Brief Description: Part 1 - Rear Canopy Countersink and Tap
Went online to VAF and checked out some postings on how builders drilled and countersunk their canopy. Previously, I had drilled 1/8" holes with the plexiglass bit and clecoed the baggage compoartment together.
I tried countersinking with the 1/8" hole in a test piece of plexiglass. The centering bit held the countersink very tight but I saw some chatter with the bit. I was using a single flute countersink cutter. I tried several times but there was chatter. You can see the chatter marks in the holes on the left side of the plexi.
Since that did not work I enlarged the hole with a plexi bit to 5/32" and then tried the same countersink bit. With some freedom for the pilot countersink to wabble slightly the holes came out perfect. I treid this several times to make sure that I got my techinque down pat.
The pictures below show the first countersunk hole in the plexiglass and the screw installed.
With the proper technique working well, I enlarged and countersunk all the holes in the plexiglass.
Also drilled and tapped the holes in the roll bar.
