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Jims Web Site
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Date: 6-21-2010
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Number of Hours: 20.50
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Manual Reference: 6C1-6C4
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Brief Description: Fabricating the rear canopy frame
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Every once in a while, any project worthy of the name has a particularly problematic part, fabrication, or installtion. That's what has happened with the rear canopy frame.
The supplied part simply does not fit. If the height is reduced sufficiently for the canopy to fall into place, the width of the frame simply is not sufficient to extend fully between the two side rails into which it is to be installed. This bends the side rails inward.
That's not a good idea, when the side rails contain the locking mechanism that holds the canopy closed in flight. Visions of the whole thing popping open are just too real.
Further, the lofting measurements provided in the plans (and from which the supplied framne was presumably made) do not result in a frame that meets the canopy everywhere. In short, you can't fully attach the canopy to the frame using these dimensions.
I decided to make a cardboard mockup of the frame, position it under the canopy, and add or remove cardboard as necessary to get a good fit. This can be seen in the first image.
I ordered some .058 wall 3/4" 6061T6, and solicited the aid of my son, James, in fabricating a bending tool. James ran this up on his mill and lathe in about 4 hours; it can be seen in image 2.
I finally got the tubing bent, and I'll have to say it was a painful process, including blisters in the palm of my hand.
I've given up on getting the canopy to fit perfectly. There is a problem right at either aft corner. If the canopy were allowed to exit the lower fitting at an inward slope, this would work.But oif it is, the canopy latch sets at an angle, meaning it may not latch fully. That. IMHO. is a safety of flight issue. I'll shim under the edge of the canopy with foam, on either side to close it, rather than have safety of flight concerns.
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Lofting prototype
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Tubing bender
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Bending the tubing
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