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Larry Winger's 601XL Project
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Date:  6-12-2009
Number of Hours:  11.25
Manual Reference:  
Brief Description:  Made and installed roll bar

Every once in a while I question my decision to build certain parts from plans. Today was among those days. At this point, it is not about the welding, because I'm actually getting reasonably good and it is almost enjoyable. What I'm referring to is the calculations and gyrations a one-time part builder goes through to cut, fit and weld the roll bar. While it may seem simple, you are trying to hit a point in space with two angled tubes intersecting a saddle made of cut-down pipe. The "feet" for the roll bar are angled (wider in the front by 16mm), further complicating things. Then you add the fishmouthing that you must do on both ends of each pipe to leave the smallest gap possible in preparation for welding. Yikes! I took a vacatioin day to finish this installation. I never would have guessed over 11 hours for this one triangle of steel. Let me tell you the good news: It came out great and I'm super glad to have some rolloever protection. My welds are good and I can check off one more item on the way to a flying airplane. I'm quite close to having everything in place for the actual canopy installation. However, unless I change my mind, I think I'll wait for that until very close to the end of my project. Because of the fact that the cockpit area is right under our garage door when it is up, I would always be fighting to keep from messing up my canopy. My worst case scenario involves me working in the cockpit -- canopy open -- in the closed garage. Then Joy comes home, garage door goes up, canopy assumes a new, rather unconventional shape. No thanks, I think I'll pass on that and move on to something else.
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Canopy frame in line with back seat rivets

Canopy frame in line with back seat rivets

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Roll bar in place with temporary hose clamps

Roll bar in place with temporary hose clamps

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That's a lot of head room!

That's a lot of head room!

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