Cozy

Chapter 18 - Canopy



The Plan

In this chapter we will build the form for the turtleback, build the turtleback and bulkheads, install windows, fit the canopy,build the canopy frame and fuselagetop forward to the F28 bulkhead, install the hinges, locks, latches, and cockpit vents. If this sounds like a lot , that's because it is!



Here is the jig, it is one of the most complex ones we use. You can see it is tapered in, in all directions. The farther back it goes it gets shorter, thinner, and smaller.

I made the bulkhead prior to glassing the inside of the turtleback. This allowed me to have a chemical bond for the rollover protection bulkhead. I made the inside layup and bulkhead addition layup at the same time.

The plans call for some aluminum strips to be used to keep the foam aligned. I now have this affinity for fiberglass, so I made mine out of glass. One suggestion, once the foam is in place don't be afraid of putting in a little dab of 5 minute epoxy to help secure the foam and keep it from riding up out of shape. I could get the foam to lay in place but when I worked it, it would shift and not be aligned.

Here the turtleback is glassed on the outside with the window holes cutout.

Here I have cut the windows to size and floxed them into place. Then clecos were used to keep the glass and window tight together. Later the inside is glassed to add additional strength to the window frames. If you get some flox or epoxy on exposed plexiglass, LEAVE IT ALONE! Don't touch it! it will harden, and will pop off with a little pressure from a razor knife or screwdriver.

While procrastinating about installing the canopy hinges, I went ahead and made the aluminum parts for the latch. Here they are all assembled, but not completed. I still have to "finish" them, get them final smooth and hopefully anodized. I may remake the latch handle, just not happy with how it came out, but it might clean up fine, we'll see.

Boy a lot of work went into this picture. Guess I should have taken a few in between. The turtleback is installed without the hinges in place. I am going to install the hinges in a fashion similar to Wayne Hicks. The canopy is cut to size, spraylatted, taped, and floxed in place. The support boards for the foam are installed and the fuselage is taped to prevent the canopy frame from sticking to the fuselage.

OOOPPPSSS!! Ther sure is a lot missing here. Should have taken more pictures. This is the finished instrument cover, I messed up a bunch of clothes doing this work. It seems that I was bent over working upside down in there, attaching the cover and glassing the attachment areas. My clothes took the worst for it.

Here is the 45 degree cut you need to do so that you can seperate the canopy from the instrument cover. This was much easier than I had feared.

The hinges were another point where I dislike the looks of the plans method. The hinges stick out and look like a drag bucket. So I wanted to keep them inside and covered up as best as possible. I worried way to much about the placement. If you are concerned like me you will automatically keep the in a little tighter and they will be ok. No special recalculations, movement positions, or anything! Just keep them where they need to be just more centered toward the airplane, maybe 1/8 inch in and 1/4 inch toward the rear. Then they will match up with your hard points and operate properly.

Here the latch is installed. It takes some more tweeking of the system to get everything operating smoothly and together. I'll have another mod here when I'm done, cause I installing a Ford door lock to actuate it from outside when it's locked.

Once you have the canopy hinged and latchable, you install the lift assist. I just hope I don't use mine up before it's ready to fly.

The handles sure make it easier to get in and out. Just follow the plans. Piece of cake or is it pie?

Again, follow the plans, you won't have any problems. I did both in a short day.

All those layups in the rear help hold the engine on the plane, and allow the engine to push you through the air. They are just as important when you've had to change out you centersection spar.

I call this one the canopy catch, BUTT. I think there is a distinct possibility of it catching something else when you get in and out of the plane. I make it a habit of leaving this in the closed position during the build. This way if it is latched closed when you close the canopy it will rest on them and be easier to reopen when you need to get in. And not be prone to catch something important whe you get in or out!



Home | Chapters | Links