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Kupe's Zodiac 650B
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Date:  7-9-2014
Number of Hours:  1.50
Manual Reference:  6-C-6
Brief Description:  Canopy Cut in Two - Begin Front Canopy

Continued where I left off yesterday by marking a line on the canopy bubble between the two rear frame hoops to split the bubble into two parts. I had been dreading this task for a while and had read some real horror stories of broken or cracked canopy bubbles. In my case, this was a non-event (although I did hold my breath a lot!).

I decided to make the cut while the canopy was resting on the frames instead of removing it to a work bench. I like how this turned out as the canopy was well supported and locked into place with gorrilla tape. From start to finish, the cut took about 10 minutes using a Dremel and moving very slowly with it. The cut is near perfect - I will still need to file/sand the edges a little since there's only about 1-2mm between the halves due to the narrowness of the Dremel cutting wheel.

After completing the cut, I removed the back section and took it back down to the basement until I'm ready to install it. Figuring my luck would hold, I started drilling out the forward section, matching it to the already-drilled holes in the rear and side frames. I used the Zenith-recommended acrylic drill bit (5/32") and held the bubble tight against the frames as I was drilling to avoid abrupt "punch-thru." Using a slow speed on the drill and light pressure against the acrylic was the key - the bit slowly and smoothly reamed its way through the plastic and came through the back side in a very controlled manner. Next up: A little trimming along the bottom sides and installing the forward frame.
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Right after the big cut. Cutting it in place worked very well.

Right after the big cut. Cutting it in place worked very well.

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After drilling out the bubble to the rear and side frames with clecos (and handles) in place.

After drilling out the bubble to the rear and side frames with clecos (and handles) in place.

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The canopy propped up to check clearances when opening and closing.

The canopy propped up to check clearances when opening and closing.

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