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Date:  8-5-2009
Number of Hours:  2.50
Manual Reference:  
Brief Description:  Canopy

BIG CUT DAY

This is probably the scariest thing I've done on the plane so far.

After measuring and re-measuring the line for the cut, I moved the canopy to the table for the cut. I mounted blocks of wood on each side of the canopy to keep it from shifting. Then, I put a box under the canopy with foam to support it.

Then, I started working down the line making the big cut. In practicing with the SonicCrafter saw, I found it pretty easy to just follow a line. (It cuts straight good.) So, I started in the middle and just started working the first half. I stopped often and taped the pieces on the top and bottom. (According to what I've read, you don't want the blade to get too hot... so I waited between cuts.)

Next, I finished the other side. I carefully filed the edges.

The cut ended up being much less stressful than I thought it would be.
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Practice holes

Practice holes

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Canopy supported ready for the cut

Canopy supported ready for the cut

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Cutting and taping

Cutting and taping

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