No sweat: Bennair; Dunnatt
We have been using the oversize hole process on the Rocket canopies since 1994 or so. Many aircraft used that exact process too.
Drill the hole to match 1/4Ē OD fuel line, and cut the line to match the thickness of the plexi. Use tinnerrman washers and #6 screws to hold things in place - donít tighten the screws totally. If need be, you can use a slightly longer piece of tubing as a shim if the plexi does not quite lay down on the tubing
Donít use the attach screws to force the plexi to conform to the tubing if the plexi does not quite follow the tubing shape (under 1/16Ē or so), or as it was with clecoes.
Drill the plexi with a step-drill on low RPM.
Build up your normal fiberglass fairing between the windshield and slider, and along the aft & side skirts.
Use household exterior caulk of your color choice to waterproof the slider plexi along the side and aft fairings; attach with the suggested fasteners. Before final assy, lay a length of masking tape along the metal fairings to keep the caulk off of the exterior
Do not use silicon caulk - just the inexpensive water based stuff.
The caulk is amazing regarding how long it lasts. Never did hear of anything coming loose.
I have never heard of a Rocket canopy cracking when this process is used.
"Not everyone needs a Rocket. Some folks, however, shouldn't live life without one.
You know who you are."
Budd Davisson, 1997