I reassembled the subpanel along with the hinge blocks and clecoed on the top skin.
I drew a centerline down the aft tube on the canopy frame. This will be used to ensure the holes drilled through the top skin will go into the center of the tube.
Several other builders have commented that some of the welds prevent the skins from laying down properly. The instructions mention this, but a picture is much more clear. Here you can see that the weld would push the skin up about 1/32″ or so.
30 seconds with the vixen file and the weld is nice and flush with the angle.
The instructions also mention that the flange needs to be filed square with the face of the forward channel through the center. A few minutes with the vixen file also took care of this. Sorry for the blurry picture.
I clecoed the skin to the forward channel of the canopy frame and drilled most of the aft tube (the one I drew the centerline on). I’ve seen a number of other builders have a problem with these holes not lining up with the centerline, but mine was almost perfect.
I fit the canopy frame for the first time, but almost immediately I had an interference problem. I couldn’t get the canopy frame far enough forward. I had anticipated interference from the hinge spacers, and a quick check with a mirror confirmed that was the problem.
I pulled the spacers (which involved climbing under the subpanel and removing the hinge blocks which was a pain in the ass). I trimmed 3/16″ off the back edge.
I reinstalled the hinge blocks and spacers and then reinstalled the canopy frame. Another builder commented that using a strap helps pull the skin down tight.
That resolved the issue. I now have almost 1/8″ clearance between the hinge arm and the spacer. Do yourself a favor and cut at least 1/8″ off the back of these spacers from the dimension Van’s specifies. It will save you a lot of headaches.
With the hinge spacer interference resolved, I could get the canopy skin almost all the way forward. I’m still getting some interference somewhere because I can’t seem to get these skins any closer. I have almost 1/32″ on the left side.
On the right though, I have almost 1/16″ gap. I need to determine where the interference is so I can pull these skins tight.
