Title: The Big Cut
I'm trying to get the canopy work done before it turns cold here in Kansas, and today was the day. Started by going to home depot and buying some boards, because I've finally exhausted my supply of scrap lumber.. A couple of days ago I trimmed off up to the mold line with a dremel saw max and the wheel that Larry Larson recommended in his excellent kit planes article. It worked fine for that up on my shop tables. For THE BIG CUT I felt like I'd rather have it low enough that I could get to the center without standing on a stool so I built a small pallet and did it on the floor. The pallet was made from 1x4" pine across a couple of 2x4s. I ran a few strips of duct tape across the bottom of the canopy to keep it from splaying out and padded the edges with scraps of the foam that the canopy frame was padded with as shipped from Vans. After the pallet was complete, R.J. helped me flip the canopy over onto it. Easy access to all areas for cutting, but the trade off here is that with it sitting this low I knew I would have a problem getting the saw max all the way to the edge. I laid down 3 layers of blue tape on each side of the cut line to make a sort of ditch or cut guide and just cut it with the Vans's supplied disk in my 90* die grinder. Made about 4-5 passes, starting at the edge, running up to the center, then switching sides. After I judged it was mostly through, I started cutting all the way through at one edge, went up about 6 inches, clamped the edge, then went to the other side. After I got both sides started, I went through in the center about 3" on each side of centerline and then duct taped the cut line so it wouldn't sag when the two halves got close to coming apart. I went back to the lower edges and cut them about 4-6" at a time, alternating back and forth and duct taping as I went. It was about 70* in the shop, but the afternoon sun had been shining in through a big window directly on the canopy for a couple of hours so it was probably a little warmer than that. No drama, but I'm glad it's done!


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