RV-8 Canopy

[gkelson]

Van's instructions call for enlarging the rivet holes that attach the plexi to the tubular frame with a #27 plastic drill. I cannot locate one. Avery used to have them but discontinued selling them because of manufacturing defects. What do you recommend? Can I use a 5/32? Will it be too big?
Gary Kelson

[brad walton]

I purchased the set of five plexiglass drill bits from Avery Tools for about $25.00. I started with a 3/32 drill bit and drilled through the plexi to the canopy tube to mark where to drill on the tubing. Go slow and maintain low pressure so the drill bit does not crack the plexi as it emerges from the back side. I then removed the canopy from the frame, drilled the frame separately and enlarged the plexi holes to 5/32 with the plexi drill bit. Carefully deburred both sides of the hole in the plexi. No cracks so far (300 hours)