Staring into the Abyss
Perhaps we can split the cost of the primers, etc.
Dave, If I end up going this way, yeah, lets definitely split the cost.
there is enough space to make a nice corner bead from the inside to the back rear canopy.
Not sure what you mean
- siderails offset towards the inside by .125" achieved by inserting two .063" spacers where the forward tipup frame meets the siderails, the position of the "ear" from the tipup frame is now just on the other side of the siderail as per plans. beveled the ear to fit.
- attached 2 .063" strips on the outside of each siderail (ordered some extra strips, the same as used on the inside of the rollbar), spacing the outside skirt out and flush with the fuselage, creating a gap for a nice bead on the inside.
OK, I get that. I could probably do those mods without too much trouble, need to think about it some more.
turned out great. only thing we forgot was to slightly angle the rollover bar on the bottom, so it sits maybe 10/32" or so higher than per plans.
I would think that might be a good thing, especially for taller pilots!
For another perspective, I built both the frame and rollover bar to plans. I fitted my canopy so I had the correct gap over most of the forward deck and the top of the rollbar/frame area. Since the canopy had to fit in the side frame and there was no way to put the necessary gap there, I had to allow the gap to lessen as it approached the sides.
Makes me worry that you would have high stresses in these areas due to differential thermal expansion, but since you also screwed this area...
However, I did have one frustration with my fit: before you glue, make sure the forward deck and skin are riveted on and all the frame is complete, including struts and latching mechanism. I added my struts and forward skin later and it shifted the fit of the canopy.
Good advice, thank you.
It now occurs to me that to do this "right" meaning consistent gap everywhere, the rollbar needs to be 1/2" narrower than plans, not the 1/4 I had mentioned, because the side skirts require 2 bondlines each of sika. And the sideframes need to be 1/4" inboard of the plans location, as indicated by Bernie.
I just can't believe that in all the reading I had done about using Sika, that this wasn't more clear - that there are significant mods required in order for this to work properly. It really makes me wonder whether people are building these with their canopies overlapping the fuse by a quarter inch, or whether they are screwing where the bond thickness gets too small? I don't really want to put any holes in the canopy if I can avoid it (this is the second canopy for this project - the first builder cracked the canopy at 2 drill holes, lost faith, and sold the project). Well, at least now I think I know what my options are:
1. Modify the rollbar to be 1/2" narrower than it already is (not even sure this can be done, need to look at it), same goes for the canopy frame (somewhat easier). (Bernie's approach)
2. Live with the reduced bond thickness and drill and screw the canopy in those areas. (Flion's approach)
3. Build it per plans (I think Chad Jensen came to this conclusion after staring into the abyss as I am doing).
4. Build it per plans except stick some Sitka in too (not sure what this accomplishes except adding weight and cost)
Thanks again for the input gents. Any other thoughts?