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| Completed Canopy Frame |
The canopy Frame is designed to pivot at the extreme FWD upper edge. The canopy is designed to pivot 90 Degrees Vertical to allow plenty of room for entry. At the 90 degree position the canopy is removable due to a slot in the canopy hinge fittings. The Fwd portion of the frame is built up similar to the FWD fairing. The process starts by bonding a horizontal foam shear web to the two canopy side rails. The side rails are made from laminated 1/4" birch Plywood. Multiple pieces are laminated together and then a final Bevel cut is made on the table saw. After the foam is Bonded to the shear web, a light layer of fiberglass and epoxy is laid. The main purpose of this ply is to protect the foam in the event of a fuel leak.
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| Canopy shear web and rails |
The foam formers are added after the glass cures.
As mentioned earlier, all foam to wood Joints are made with 5 minute Epoxy. This greatly speeds up assembly time.
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| Canopy frame with FWD stringers and formers. |
The formers and stringers are added similar to the FWD fairing. 1/32nd Birch Plywood fabric transition gussets are also added. The alignment of the rear most former is critical as it must be angled to clear the control stick and provide a FWD flange for the actual canopy to sit on.
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| Canopy partially open |
Unfortunately the Shop ceiling is not high enough for a full extension of the canopy. Once opened there are cable guy braces and a small strut to keep the canopy in place when opened. The rear frame and Yarmulke were added to the rails during the early build. The next step is to make the windshield template.
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| Windshield in place |
The Windshield is a flat wrap design, there are no compound contours that would require heat forming. The purpose of the Yarmulke was to remove compound contour and act as a sun shield. Because of the number of variables with a plans built frame, the actual windshield profile must be developed from a template. I used taped together poster board sheets to develop the template. Once this is derived, it is transferred to the Lexan. The Actual Windshield is .032" thick therefor it is very easy to trim with the use of metal tin snips. The final attachment to the frame will be with polyurethane automotive windshield adhesive and countersunk 1/8" pop rivets. These are really nothing more than clamps used to hold the canopy down for cure.
Looking good, I was wondering how you were going to enter and exit. I like it.
ReplyDeleteWell, I still didnt have it all quite figured out, you will have to be a contorsionist to get in and out of the Prototype, I did not add a wing walk, There will be a step on the landing gear however. The redesigned wing will not only be 29 lbs lighter, but it will have a wing walk and grealy simplify assembly.
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