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Now for the canopy

I've avoided the canopy as long as I can, the fuselage is built up as far as I can so it's time to dive in.... Spent quite a few hours on the the initial tweaking of the canopy frame, getting close but probably need a few more hours of bending to get it to fit the canopy bow. This feels a lot more art than engineering as you don't know what happens to your fit until the canopy is on.
Head on:
Head on view of canopy frame, getting closer by Dave Hock, on Flickr
Side:
Gap on left side still a little "looser" than right side by Dave Hock, on Flickr
Spring clamps:
Untitled by Dave Hock, on Flickr
 
That was after 6-7 hours of looking, bending, swearing and then just saying ----it and cutting. I am following your write up on the Sika process and after reading many articles planning a little bit of hybrid. My plan is to bond to the "hoops" and center then screws along the bottom edge and bond the aft skirts to the plexi... at least that's what I thinking now. I need to leave the forward skin off until I do my avionics and wiring over the winter but wanted the canopy done now before it gets cold in the garage (I'm in CO also).
 
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Colorado RVs

That was after 6-7 hours of looking, bending, swearing and then just say ----it and cutting. I am following your write up on the Sika process and after reading many articles planning a little bit of hybrid. My plan is to bond to the "hoops" and center then screws along the bottom edge and bond the aft skirts to the plexi... at least that's what I thinking now. I need to leave the forward skin off until I do my avionics and wiring over the winter but wanted the canopy done now before it gets cold in the garage (I'm in CO also).

You're choice but I would Sika the whole thing. You're were a member of our Google Group, Colorado RVs. For some reason, I don't see you in the list. If you would like back in, shoot me an e-mail (see signature below).
 
Wings on!!!

First time the wings have been on the plane. It’s sure nice to see them out of the cradles. Now to check sweep and set incidence. Getting closer.
 

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My plan is to bond to the "hoops" and center then screws along the bottom edge and bond the aft skirts to the plexi... at least that's what I thinking now.

That's what I did, though I sealed the canopy skirts with Sika. Expect the canopy to spread the frame a bit (which you likely already know). I had straps pulling mine together by about an inch (from fit) and it still sprung beyond the previous fit.
 
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Fuse has has paint

Time to start putting her back together I guess

80-pxl_20201019_201816856_1__ae56cfd16f4e11267264c3ba0891cec8b4aaacea.jpg
 
Canopy is bonded!

Boy I think I spent more time thinking and sweating about this than
the actual job. Some great tips from Larry aka wirejock on his process,
THANKS Larry! Some pictures of the initial fit tonight. I went onto
the roller tracks with zero friction, I think my canopy expanded the f
rame less than a 1/4", I was concerned but in the end worked out well.
I might do a few thing different if I did it again but overall it worked.
For me I will rivet and screw the side skirts and Sika bond the aft
skirts and attempt to do it with the aluminum. Whew, on to the next job.





 
Canopy

Looks good Dave! By the way, I pulled some of the plastic protective film and the plexi looks pristine underneath. I think I'll leave it on a bit longer.
 
last pre-assembled pic I hope.

Really happy with the way the pants turned out. Also, cool seeing my N number in actual paint. Changes nothing but makes it "seem" more like a real airplane.

I am very happy with my painter!

https://cimg0.ibsrv.net/gimg/www.au..._d61307dc4f3b217607292f4e920aecb73b432746.jpg

https://cimg9.ibsrv.net/gimg/www.au..._9e5e5527e6e7fcbda539647d67d72e6641ecfbe1.jpg

https://cimg0.ibsrv.net/gimg/www.au..._4119bc64c9b5d64388966ce25c9ebb20008f1c48.jpg

https://cimg2.ibsrv.net/gimg/www.au..._1f37a76bb5b3fc9f53701b5b49810de7c642e976.jpg
 
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Encouragement from Cleco.....

My wife, Tracey, and I continuing with wiring. Cleco the wonder dog cheering us on!
 

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Skirts

I really wanted to give it my best shot at fitting the aluminum aft skirts as well as side skirts, but was concerned that the fit of the aft skirts would not come out well. I'm happy with these results. My slider seems to have small gills (gaps) at the lower aft corners, which I think is the most common challenge with getting the fit right on the skirts. However, I'm going to live with this. Tops and upper sides fit tight.

Do you have any idea how happy I am to be done with the slider???????
 

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Ryan-those skirts look fantastic! I tired a couple times before throwing in the towel and going with glass. Nice work!!!
 
I do indeed know what it feels like! Congratulations they look great! I just finished my 7 canopy a couple of weeks ago and while I Sika bonded the frame bows to the canopy I used aluminum for side and aft skirts as I liked that look. I spent many hours hand shaping the aft skirts also. I also have a gap a lower corners and little down the side (less than pencil)... I want to keep fusing with them but my wife is saying leave well enough alone and she is probably right. You can see a couple pics in my Flickr page if you like.
 
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Beautiful work Dave! Yes, I really like the look of the aluminum skirts too. Love your picture log...it's excellent! I visit it from time to time to see how things go together. Next up are the wheel & brake assemblies.

Ryan
 
Initial Wing Fit: Milestones=Motivation

Trying to get as much done in my home garage on my RV7 project before I need to worry about moving to a hangar. I have some great experienced helpers close by that made this a very easy process yesterday morning.

I'll do all the work I can with the wings on, then remove them for later permanent install at the airport.

Next steps after the wings will be to permanently mount the tail pieces, then install the gear and hang the engine, all in the home garage.

Ryan
 

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Wing Tips Done! & Jake Wins High Jump @ Air Force Invitational

Now that the wing tips are done, I believe this completes the initial fit and rigging of wings, flaps, ailerons, and corresponding controls. Too bad it's all coming off tomorrow!


Oh, and since I'm sharing good news of the day:

https://goairforcefalcons.com/news/...wins-high-jump-at-air-force-invitational.aspx

We could only watch the live stream from home.
 

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Now that the wing tips are done, I believe this completes the initial fit and rigging of wings, flaps, ailerons, and corresponding controls. Too bad it's all coming off tomorrow!


Oh, and since I'm sharing good news of the day:

https://goairforcefalcons.com/news/...wins-high-jump-at-air-force-invitational.aspx

We could only watch the live stream from home.

This is a clean facility Ryan could easily compete with Martin J Filiatrault in neatness :)
Congratulations to your son Jake ! Good job young aviator!
 
Finally finished my last wing skin rivet (besides tips and body fairing). Now to figure out how to store both wings in my basement shop and start reconfiguring my small adjacent garage shop for the SB body construction, expected to arrive hopefully in May..
 

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Finishing SB wings is a huge milestone! Congrats Jeff! Your project is looking great!

I've been jockeying assemblies trying to free up build space too in my garage for the past 3.5 years. At different times, parts have been placed in the master bedroom, hung up in the home office, on couches, on beds, and stored in upstairs bedrooms, etc., and thus now I know what "home built" really means!

Ryan
 
Finishing SB wings is a huge milestone! Congrats Jeff! Your project is looking great!

I've been jockeying assemblies trying to free up build space too in my garage for the past 3.5 years. At different times, parts have been placed in the master bedroom, hung up in the home office, on couches, on beds, and stored in upstairs bedrooms, etc., and thus now I know what "home built" really means!

Ryan

Thanks Ryan, yeah it still hasn't sunk in -such an incredible thing to be doing, building your own plane! It seemed like all the wing skin holes & rivets took forever but eventually it's over. It sure is nice having real airplane parts around the house -going to miss them when I have to take them to a hangar.
 
Finally finished my last wing skin rivet (besides tips and body fairing). Now to figure out how to store both wings in my basement shop and start reconfiguring my small adjacent garage shop for the SB body construction, expected to arrive hopefully in May..

Is that an old Honda CBX in the back of the shop I see?
 
Is that an old Honda CBX in the back of the shop I see?

Yes, a 1982 CBX... my dream bike upon graduation from high school back in 1985 that I forgo buying to avoid financial burden as I went off to college. 30 years later I bought this one from a good friend at work! 16k miles and in great condition -super smooth and sounds great!
 
With the lighting in those photos, and the reflective wing, all I could think was Bow-chickee-bow! :rolleyes:

It is becoming quite the lounge, wish I had some blue taxiway lamps to accent it. The empennage is hanging in the more serious workspace: my wife's and my covid-days home office.
 

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It is becoming quite the lounge, wish I had some blue taxiway lamps to accent it.

You know, I just may be able to help you out. I have a Blue taxi lamp that was removed from Corona Airport when they upgraded the lighting. I also have the base for it but it's quite heavy. I paid $150. Interested?

-Marc

Taxi light.jpg
 
Windscreen install

Please find some photographs of my installation of the windscreen which I have completed this week

This photo is when I had installed the small brackets to hold the windscreen in place and then I put a fillet of epoxy with balloons between the windscreen and the top skin.

https://flic.kr/p/2kHgLSB

The next photo shows the fibreglass strips being installed to provide the bulk and strength for the fairing.

https://flic.kr/p/2kHkpmA

This is the finished product. I have used epoxy with balloons to smooth out the surface and to streamline the shape.

https://flic.kr/p/2kHkpVX

This was the last major job I had to do on the fuselage. I have some minor jobs still to do and then I can paint the fuselage followed by installing the wings.

Cheers,
 
Please find some photographs of my installation of the windscreen which I have completed this week

Nice job Gordon. And how timely for me, I will do this step soon.

Can I ask please, did you overlap the canopy side skirts with the windshield fairing? Or do the but together? I'm afraid the side skirt may not want to go under the windshield fairing one odd day and catch/bend.

Regards,
 
Windscreen fairing

I have overlapped the windscreen fairing over the canopy side skirt as there is a small gap between the side skirt and the windscreen. This smooths the airflow in this location plus reduces the chance of excess wind noise.

I placed 2 inch wide masking tape over the front of the canopy and the side skirt, plus put packing tape over top of the masking tape. This produced a non stick environment for the fibreglass (i.e. the packing tape) plus the thickness of the two tapes once removed gives about 5-10 thousands of an inch gap between the canopy and the fairing to allow the canopy to slide in under the fairing easily. Plus the masking tape makes it easier to remove the packing tape from the canopy.

I also overlapped a couple of layers of fibreglass from both the front skirt and the top fairing at the side skirt location which helps strengthen that location. The drawing also recommends that the top fairing should be around 80 thousands of an inch thick. The combination of the thickness and the strength of the fibreglass layers makes it quite strong. Plus the fairing comes down level to the bottom of the top skin to give more support to the fairing as it is attached to the fuselage side skin.

However, I wouldn't use the fairing to take my weight while I am climbing in or out of the cockpit but the fairing should be strong enough and won't flex to contact the side skirt.

I hope this has helped and good luck with your project.
 
Build update

Haven't posted lately as I was away from my project for a while. You know how it goes..life. But I'm happy to report I'm back at it and am representing the SLOOW build folks out there. ;)

January this year I started with digging out the longerons and got them bent. Mated up the aft and center sections. Got all the skins on and built the forward section. Then all the disassemble, prep, prime and paint. Put it all back together and lots of riveting.

Finished up today and got my fuse dolly made. And flipped my canoe!!


http://[url=https://flic.kr/p/2kGYvw7]20210324_204712 by Francis Jr, on Flickr[/URL]

http://[url=https://flic.kr/p/2kP2wUP]20210325_192931 by Francis Jr, on Flickr[/URL]

http://[url=https://flic.kr/p/2kP6B8Q]20210325_201601 by Francis Jr, on Flickr[/URL]
 
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