How to sand canopy edges

[Ben Ellis]

This may sound like a dumb question, but when you are trimming and smoothing the edges of the canopy, how do you position the canopy to get to the edges?

I’ve read a lot about how important it is to not lift or move the canopy until you’ve smoothed the edges, but if you are trimming it on a workbench I assume you’re doing it with the edges down on the table. So are you carefully lifting one side with one hand while you smooth the edge with the other, or are you flipping it upside down somehow so the edges are easy to access, or are you using some jig to hold it off the bench?

 

[jsalley]

This may sound like a dumb question, but when you are trimming and smoothing the edges of the canopy, how do you position the canopy to get to the edges?

I’ve read a lot about how important it is to not lift or move the canopy until you’ve smoothed the edges, but if you are trimming it on a workbench I assume you’re doing it with the edges down on the table. So are you carefully lifting one side with one hand while you smooth the edge with the other, or are you flipping it upside down somehow so the edges are easy to access, or are you using some jig to hold it off the bench?

I did mine (RV-12iS) with the canopy upside down on a table. The plexi is protected by the vinyl film, and I had a moving blanket under it. Awkward at times, but made it easy to spin around to work on each edge.

 

[fl-mike]

Upside down card table, straps between pairs of legs to make a cradle, put the canopy in the cradle upside down. (Protective plastic on the canopy of course!)
I found this to keep everything under control and safe.

 

[ChiefPilot]

I did the same as others have mentioned - upside down on top of a moving blanket. Aside from that, I had a couple of "straps" of duct tape going across to keep it from "splaying" outward. I like Mike W.'s approach better though.

 

[skelrad]

Upside down on a moving blanket for me too. I also had my big portable infrared heater going to keep the plexi nice and warm just in case.

 

[Ben Ellis]

Thanks guys, this is all very helpful. Upside down definitely makes it a lot easier.

 

[lipper03]

My opinion is just be careful. I did the upside down method, but I’d agree you can’t just get after it, especially the outer edges in the air, use a hand to keep it steady. Lift it carefully, don’t just yank it off a table with one hand, haha. Seriously though, it’s not cracking just looking at it, it can take careful work practices.

 

[wirejock]

Two saw horses. Clamp and old blanket to make a hammock. Lay the canopy in upside-down. After cutting, use a multi oscillating tool with a sanding pad to smooth the edges. When you think you're done, wipe the edge with a wet paper towels. Any deep tooling marks will be easy to see.

 

[skelrad]

Two saw horses. Clamp and old blanket to make a hammock. Lay the canopy in upside-down. After cutting, use a multi oscillating tool with a sanding pad to smooth the edges. When you think you're done, wipe the edge with a wet paper towels. Any deep tooling marks will be easy to see.

Note - like Larry said, use a multi oscillating tool to SAND afterwards if you want. Don't use it to cut! The tool will cut the plexi with very minimal dust compare to a die grinder, but even with a high tooth blade, you're playing with fire. On the advice of a few people (internet experts are always confident, no matter how wrong), I used a multi tool. I got 90% done and would have said it worked great....until it didn't. I ended up having to cut out a chunk of the edge to get rid of tiny cracks that were created from the vibration of the tool. Just use a cut off wheel like Van's says.

In terms of edge finishing, I also found that a plexi edge scraper works really well after any cut marks are sanded down with coarse sandpaper. I bought one for $10 on ebay and it works extremely well for smoothing out the edges to the point that finish sanding isn't even necessary most of the time.

 

[wirejock]

Dremel Saw Max cuts plexiglass like butter.

 

[Marlonyoung]

Like they said upside down in a cradle, I used an old blanket stapled to the cradle I made with old two by fours