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Kupe's Zodiac 650B
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Date:  6-26-2014
Number of Hours:  1.00
Manual Reference:  6-C-3
Brief Description:  2. Aft Rear Canopy Frame Cut

Drilled the rollbar attach tabs then attached it to the upper longeron with clecoes.

Cut the ends off of the aft rear canopy frame based on yesterday's measurement (after re-checking a couple more times) and began the process of fitting it. I was afraid to cut too much, so I ended up cutting off smaller and smaller amounts at a time until it fit well.

Next, I needed to tighten up the curve in the hoop a bit so I screwed two blocks of wood to my work bench with enough distance between them to easily slide the canopy frame through it, then proceeded to lean gently yet firmly on the hoop as I stepped it though the blocks. I'd heard horror stories about other builders crimping their frames so I'm trying to be careful and learn through their mistakes. After about 5 round trips between the bench and the plane (about a 3 foot round trip!) I got the hoop where I wanted it: Resting in the rollbar cradle, ~5mm behind the left/right side frames, and 1/8" inboard of the canopy skin on both sides.

Sorry about the foggy pics - I had just broought my camera out from the air conditioned house into the warm, steamy garage.
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Right side of the rollbar after drilling and clecoing.

Right side of the rollbar after drilling and clecoing.

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Right side of rear frame with 5mm spacer.  Needs a bit more filing to set the angle just right.

Right side of rear frame with 5mm spacer. Needs a bit more filing to set the angle just right.

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Left side in position.  I might have to remove that rivet to make it fit...

Left side in position. I might have to remove that rivet to make it fit...

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