Due to the fiberglass canopy fairing at the tip up joint on my RV6 departing during flight I needed to make a new one. Luckily an airport neighbor returned what was left of the original one and I sort of used it as a pattern. I didn't really look forward to laying one up with fiberglass so I thought I would try to make one from some extra .020 aluminum I had. Kevin my RV8 builder friend assisted with design, hole alignment and dimpling.
We decided it would be easier to handle if it were made in two pieces and overlapped them at the center top. I have always been fond of powder coating and find it simple to apply and more durable than paint. The biggest issue is having a big enough oven to bake the coated part. I recently received a new catalog from Eastwood Company which contained a yellow powder that looked like it matched my plane color almost exactly so I thought I would try it. I decided if I didn’t like it I could strip it and base coat/clear coat it later.
Below are a few pictures as the project developed. I used every third screw of the existing canopy mount to secure the fairing. I believe I will remove both sides and add a small bead of sealer just to prevent water getting under the leading edge.
Photo 1 Initial Layup
Photo 2 Close Up - shows rolled leading edge
Photo 3 Scuffed and ready for powder coating
Photo 4 Powder applied but not baked on
Photo 5 Left side coated, baked and cooling in oven
Photo 6 Stainless screws coated and baked
Photo 7 Left side installed
Photo 8 Right side installed
Photo 9 Added a lift handle