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Alaska Sonex
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Date:  6-26-2011
Number of Hours:  6.00
Manual Reference:  SNX-D01
Brief Description:  Canopy 1

Heated my work space up to the mid 70's. Began fitting the canopy. My wife was assisting as there is just no way to handle the canopy and bandsaw by yourself. Used a wood cutting blade on my bandsaw. I was going to use a vibrating type saw but found that it just was too difficult to maintain good straight cuts- on my practice materials. Others have found it to be easier.

The bandsaw makes quick but somewhat rough cuts, i.e., lots of stress risers. I used 80 grit paper on my belt sander to knock these down and then used 120, then 180 grit by hand on a block. It really isn't difficult and, in it's self, not even time consuming. Unfortunately, you have to do this after every cut and this does get old.

It took multiple on and off fittings but finally came out okay. There is an area or two which could be better but it will work. You are to leave an approximate 1/16 gap between windscreen and canopy. Some of mine are a little more.

I want to look at a flexible seal for the the canopy; mostly for the rear; I'll see what I can find. People do comment that rain will come in via these points.

Still need to drill the retaining screw holes and this is where people have met with tragedy. If I break my canopy then I am done for another season. Can't let that happen. I purchased special drill bits for this process. The windscreen was easy; this, I've heard is not.

As an aside, I find that I have a generous amount of headroom with the lowered seat mod. It is a great relief. Pic #3 shows canopy temporarily on; the oddness around the edges is the protective overwrap -not bad cutting.
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The raw canopy with the Sonex marked edges.

The raw canopy with the Sonex marked edges.

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The second cut

The second cut

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First time inside with the lid on -SWEET!

First time inside with the lid on -SWEET!

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