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Date:  6-18-2012
Number of Hours:  2.60
Manual Reference:  34-07
Brief Description:  Final Drilled Canopy Holes

Decided to follow advice of other builders and use a step drill (Unibit - 5/32" step) to final drill canopy holes instead of using a #27 plastic drill bit. Other builders mentioned use of a hand drill but no luck finding one so tried to run step drill through holes by twisting with fingers. Tedious but worked fine. Felt like there was plenty of control and could back out if bit started grabbing. Countersunk edges by finger twisting a deburring bit - left a nice chamfer on edges of holes. Would I want to do it this way again? NO WAY. If I had to do another canopy, would I do it this way again? YOU BET. Results came out much better than I was expecting and the only causalty were my fingers. Also found that front edge holes could be countersunk using a #27 100-degree countersink using same technique as step drill (twisting by hand). Depth was almost perfect every time and really couldn't go too deep using finger pressure. All-in-all, very happy with the results. (page 34-07, step 3).
Page 34-07 is complete
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Finger Drilling Holes

Finger Drilling Holes

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Final Result

Final Result

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Typical Hole

Typical Hole

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