Before I left on vacation I had everything set for drilling the hinge pin holes in the canopy frame. We got home around 2:00 AM, so I only got over to the hangar for a couple of hours today. The plans tell you to cleco it all together and drill / mark the hole location with a 1/4" bit. I removed just enough clecos from the left side of the forward skin in order to lift the skin without bending it, reach in with the drill and drill / mark the hole location. Re-cleco that side down and move over to the right side and repeat. You can see the results in image one and two. Two nice marks with plenty of edge clearance all the way around.
To drill the hole through the hinge material I made a 1/4" drill guide out of wood. Clamping everything to my work bench I drilled the 1/4" hole in each hinge. Next was to slowly open the hole to 23/64" so I can use a .375 reemer to properly size the hole. I used a stepper bit to start to open the hole and then a series of bits to slowly get to the 23/64". You can see in image three the process so far. Once the hole is to size I will press a brass bushing in place.
