This evening I started making the canopy frame parts into the canopy frame. I started by measuring the width ONE MORE TIME. (It hasn't changed since yesterday and is still right on.) Figuring out how far to drill the holes apart was a bit tricky. But, 1 3/8 of an inch ended up just about perfect for both the inner and outer holes. (This is just a bit under the maximum distance of 1 1/2 inch) Before I got started, I marked all of the holes. (For both the inner and outer channels - all four sets)
I built a drilling jig to keep all of the holes in the center of the channel edge. All I had to worry about was lining up the bit on the distance line.
The plans say to beware of the strap pulling up away from the frame when making the corner. I ended up clamping the strap down and using plenty of the clamping clecos.
