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Sean's RV 7 Project
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Date:  4-19-2016
Number of Hours:  2.20
Manual Reference:  
Brief Description:  Canopy Trimming

It was another night of trimming plexi in the garage. I'm still having great difficulty with the plexi making contact to the aluminum just aft of the ears. I must put a fair amount of pressure on the plexi in this area to make contact. The left is worse than the right, but both are too resistant. Under advice of Van's and in reading other posts from builders struggling with this dilema, I have trimmed the front curve more and more for a possible resolution. The plexi is now slightly aft of the forward mark on the aluminum skin, and the aft of the plexi is within 1/16" of the centerline of the rollbar. I can't take anymore material off and maintain the overall fore and aft prescribed dimensions. I still have the issue of outward tension in that area of the plexi. I will use Sika to bond and this seems to have stopped all progress. Very frustrated and not sure what to do next. Take a chance and heat that area while it's clamped with the side skirts? Put extra Sika thickness in the area with slight clamping pressure, then try to fair it in with fiberglass later? Start again from scratch? Ughhhh!!!!
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Just aft of the ears.  Lots of outward tension by the plexi here.

Just aft of the ears. Lots of outward tension by the plexi here.

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Line indicates prior plexi sizing.  Trimmed more.

Line indicates prior plexi sizing. Trimmed more.

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Left side has lots of tension. Right has it too, but not as bad.  Can get it under the ears.

Left side has lots of tension. Right has it too, but not as bad. Can get it under the ears.

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