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Michael's Sonex Project
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Date:  9-16-2007
Number of Hours:  3.00
Manual Reference:  SNX-D01
Brief Description:  Drilling Windscreen

The windscreen was cut to the marks made yesterday, which are close to the final cut, but not quite. The final cuts will be made once the windscreen drilling is complete. I have been using a dremel tools with a cutoff wheel. This basically melts it's way through the polycarbonate windscreen material. The front and sides of the windscreen was drilled using holes in the fuselage as guides. The holes were drilled using an 11/64" drill as indicated in the plans. To drill the holes through the windscreen and bow rod I took a hint from Sonex builder Jeff Shultz, http://users.cablemo.net/~jjshultz/sonex/images/canopy/HoleCenteringTool.jpg, Jeff built a drill guide that butts up against the bow rod and allows you to precisely place the drill hole. I also used it to the the bow plate the have the correct exposure. Using this method the holes came out very nicely. Cleco's were placed in the holes as I drilled them.
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Drill Guide

Drill Guide

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Using Drill Guide

Using Drill Guide

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Windscreen Drilling Complete

Windscreen Drilling Complete

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