Tonight I did more work on the canopy. Filling, sanding, and priming. One thing that I’ve noticed and I’ve seen on other planes as well is the fill over the flush rivets seems to ‘bulge’ out from some rivets. What I believe is happening is that since my canopy is so tight I’m actually pulling the rivets through the canopy fiberglass just a tiny bit. However, enough so the bondo (which doesn’t move much) separates from the rivets and becomes a small ‘bulge’. When I try to sand these down, it doesn’t seem to work well because this bulge isn’t held tight so it moves in and out slightly. The only way to fix this is to tear off the bulging bondo and redo. I have probably 20 rivets like this. What I’ll probably do, is live with this condition for now until the canopy stretches into place better and have the canopy professionally painted sometime later. I’ll just have to live with is being a little ugly for now.
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