Nov 13, 2023     Section 38 - Canopy and Window 29 - (5.1 hours)       Category: Sec 38 CAW

Finishing up the Canopy!! I have installed the sunshade, made all the wiring, painted nuts and rivets, and installed the wiring. All good to go and another section is finished!!!

https://youtu.be/0K4t3hWyq_0

  Nov 10, 2023     Section 38 - Canopy and Window 28 - (2.7 hours)       Category: Sec 38 CAW

Almost there! final sanding of the canopy window and then on to the canopy wiring.

https://youtu.be/KPsjt5QPWNI

  Nov 09, 2023     Section 38 - Canopy and Window 27 - (3.1 hours)       Category: Sec 38 CAW

This is the one to the last work session. The only task missing now is to lightly sand the front window because there are some touch points with the back windows that are not allowing the canopy to close fully. For this session, I have installed, screwed, and glued the back window in place. It required some additional cutting, not described in the manual, as per pictures 423.1 and 423.2. Other than that, it is all moving along smoothly.

I painted the washers that support the top of the back window to match the roll bar color and it looks good. One thing I didn't like was that the fuel sealant that is supposed to be applied between the canopy window and back skins is visible from the inside and when applied, it is not equally spread. There are waves of sealant, visible from inside. It would look better if it was a straight line but hard to achieve that unless I had applied the sealant before placing the window.

https://youtu.be/TA8S3MzKe9k

  Nov 08, 2023     Section 38 - Canopy and Window 26 - (4.3 hours)       Category: Sec 38 CAW

In this work session, I finished fabricating the forward canopy window. I have installed all the sealing materials, fabricated the hinge covers, drilled the canopy deck for the guiding pin, installed the guide pin, and fabricated a tool to latch the canopy more easily. I also started installing the sunshade. I found the centerline of the window and glued the sunshade rail.

For finding the spot of the guide pin, Vans recommends using molding clay. I found that Cream cheese is better :) I had it handy and I could even eat it after use ;)

Jokes aside, I am really happy with the tool I created using the stock canopy jettison handle. When we go with the option of a remote canopy jettison handle the lock system works in the opposite direction, which makes that much harder to lock the canopy hinges in place. This tool helps to grab the lock arm from its forward face and pool it aft to lock the canopy. Worked like a charm.

https://youtu.be/ZwrN0VFKTQg

  Nov 07, 2023     Section 38 - Canopy and Window 25 - (3.8 hours)       Category: Sec 38 CAW

I am so glad I finished the fiberglass work of the fairing! Now I am on the final sprint to finish this section. The work left is installing all the sealing tapes and pads and doing the final installation of the pin guide and hinge covers. In the work session today I started with the seals. I sanded and cleaned the surfaces where I needed to glue the seals and I also installed a wire anchor to hold the LED wires in place.

https://youtu.be/1PpTXc9FoDg

  Nov 06, 2023     Section 38 - Canopy and Window 24 - (9.2 hours)       Category: Sec 38 CAW

Sanding, layering resin, waiting for 24h, sanding, repeat, repeat, mask adding filler primer, sanding, repeat...

Apart from the mistake on the finish to the aft end, I think the fairing is turning out great. I will not try to fix my mistake at this point. I rather ask the paint shop to try and fix it in the future.

https://youtu.be/eWYTEfNNohU

  Nov 02, 2023     Section 38 - Canopy and Window 23 - (4.9 hours)       Category: Sec 38 CAW

Good Lord, I hate so much fiberglassing. What a messy tedious slow process.

I laid all fiberglass strips saturated with epoxy resin as per instruction trying to make the best shape possible. Waited for it to dry overnight and fabricated the custom sanding block in the meanwhile.

While laying the fiberglass cloth, I realized I made a mistake on the shape of the aft end of the fairing. I was not supposed to use so much area of the canopy. See pictures 419.19 and 419.21. The clear void seen in the picture should be bare canopy window actually... and unscratched... I ended up sanding it thinking the fiber would lay over it. But I was wrong. I was supposed to continue the line of the aft fairing and marry with the side rail skin. Now I will have to figure out a way to feather this with the side skin later...

Now, the job ahead is A LOT of sanding..... A few hours for sure before going to the finer grits and finishing resin layer.

https://youtu.be/84qcCms2UeU

  Nov 01, 2023     Section 38 - Canopy and Window 22 - (5 hours)       Category: Sec 38 CAW

Today I started the fiberglassing work. The front canopy window was resting perfectly on the aluminum but when I clipped the 3 positions as per Vans instructions, more points of bulging canopy appeared. So I've added other clips.

After adding the clips, I laid the first application of resin with micro balloons to fill all the voids between glass and aluminum. I worked not as fast as I should have, and the filling turned out not so good. So I waited for it to dry and after sanding and cleaning, I worked on a second layer.

In preparation for the next steps, I cut all the fiberglass fabric pieces and laid them on the shelves for later use.

4 pumps of epoxy resin used.

https://youtu.be/NiV8xB76LDc

  Oct 31, 2023     Section 38 - Canopy and Window 21 - (4.5 hours)       Category: Sec 38 CAW

I continued working on the Canopy. Now the attachment to the canopy assembly frame is done and I will be moving on to the fiberglass work on the transition between aluminum and canopy window.

https://youtu.be/w1ZFlAkHSyI

  Oct 25, 2023     Section 38 - Canopy and Window 20 - (3.3 hours)       Category: Sec 38 CAW

Today I am finishing up the side rail attachment of the canopy. It starts with removing everything again for machine countersinking. I dimpled all the screw holes on the side rail skins, machine counter sunk the acrylic canopy with NO cracks, cleaned everything, and reclecoed it all in place.

After final alignment checks, I took on the riveting and attached the canopy handles with screws. So far everything is going great with this Canopy section. To me, this is the most intricate section so far. even more detailed than a fuel tank and with the most variety of techniques and materials, and precision is required. Can't wait to have it finished.

https://youtu.be/q2rOBZm2POI

  Oct 24, 2023     Section 38 - Canopy and Window 19 - (4.6 hours)       Category: Sec 38 CAW

In this step of the canopy front window assembly, I am working on the final shaping and sanding of the canopy and canopy frame structure prior to the final installation. I have reduced the length of the canopy on the sharp turn corners/sides of the canopy and now it makes more sense as to why Vans instructs us to sand the inside of those areas.

I believe I have the surfaces well-sanded and ready to go to the next step but I will do a final review before moving forward during the next work session.

https://youtu.be/GeoWYTS7UDs

  Oct 23, 2023     Section 38 - Canopy and Window 18 - (5.4 hours)       Category: Sec 38 CAW

During this work session, I am working on the dashboard glare shield. Initially, I am test-fitting everything and determining where to attach the internal GPS antenna. After finding the central location, I temporarily attached the GPS antenna and the dashboard fans. With those in place, I could map the areas that must be painted in black to avoid reflections on the glare shield.

I scuffed, cleaned, primed, and painted these areas. Next, I sanded the underneath skin of the glare shield to stick the hook and loop strip. Finally, I have permanently installed fans, GPS antenna, and glare shield, missing only the installation of the LED strip in the glare shield pocket and wiring.

10ml of primer used.
10ml of paint used.

https://youtu.be/7Ws2EoJx0zE

  Oct 20, 2023     Section 38 - Canopy and Window 17 - (3.8 hours)       Category: Sec 38 CAW

Finished drilling the canopy. I think no cracks! at least where visible. In the next work session, I will remove the side skins and see if the work was indeed flawless or not :D

https://youtu.be/alhQ-azwJ0k

  Oct 19, 2023     Section 38 - Canopy and Window 16 - (3.4 hours)       Category: Sec 38 CAW

As I continue working on the front window canopy, I find it unclear why is it necessary to sand, so much (down to 2.4mm thick), the inner side of the window where it rests on top of the dashboard notch. I understand the concept that it is desirable to have the entire edge touching the aluminum but over the notch, with the initial 3-inch sanding alone, the edge raises above the aluminum level. And there is no way to level it out afterward due to the minimum thickness required. Maybe I will understand it later as Van's is rarely to never giving mistaken instructions.

Anyway, moving forward, I made my weights to set the window in place using ziplock bags and water. I would have used two bags per weight as one of them had already to be replaced due to a leak. :)

Started drilling the first section of screws, and NO CRACKS, very happy with the overall alignment, and distancing from the forward edge of the back windows shim. I think this is turning out better than expected despite the daunting task it is in itself.

Very slow drilling!

https://youtu.be/3KR7PgCuoFI

  Oct 18, 2023     Section 38 - Canopy and Window 15 - (4.5 hours)       Category: Sec 38 CAW

Today I continued working on the Canopy front window. This thing is heavy and huge. Very hard to move around and the process of installing it requires a lot of back and forth. putting it on, testing fit, marking, removing, sanding, cutting, back on, and so on... Slowly I will get there but still a lot of work ahead.

While I had the back window off, I decided to fill the O2 tank for a leak test. I will leave it with 1500PSI and note if any pressure reduction will happen.

Filling the O2 tank is actually a very easy process, which requires a lot of attention. My supply cylinder is 3 times the size of the airplane cylinder, which is not ideal. Because of that, I am not able to get the full 2000psi pressure on, as the supply pressure reduces and equalizes with the airplane pressure. But it is enough for testing purposes.

https://youtu.be/I0xpIa1wVVE

  Oct 17, 2023     Section 38 - Canopy and Window 14 - (6.1 hours)       Category: Sec 38 CAW

Working on the canopy assembly. Installing the latching and canopy jettison systems and initial fit of the canopy frame.

https://youtu.be/0hMMgFyfpeg

  Oct 15, 2023     Section 38 - Canopy and Window 13 - (8.5 hours)       Category: Sec 38 CAW

A lot done today. I have finished the preparation of the aft canopy window. I drilled the canopy holes from inside out since the countersinking would be done from outside in, to avoid cracks, as the machine countersinking process could actually clear the crack. But, It worked so well that I had no cracks whatsoever in the entire structure. I always used VERY slow speeds for drilling and always deeper the bits on a mixture of alcohol and baking powder.

Before moving on with the canopy build, I decided to give it an initial coat of gray. I might need to go back for screws and rivet shop heads but at least the trickiest places are painted already, for example, the locking mechanism.

200ml of paint used.

https://youtu.be/ryMtXyqZiWU

  Oct 13, 2023     Section 38 - Canopy and Window 12 - (3.2 hours)       Category: Sec 38 CAW

Installing the back window canopy. so far I have no cracks and the window is sitting nicely!!

https://youtu.be/s4Z3sSIG_nw

  Oct 12, 2023     Section 38 - Canopy and Window 11 - (3.8 hours)       Category: Sec 38 CAW

The main canopy assembly is complete. Before moving forward, I will go back to the back window preparation and locking mechanism. Starting with trimming the back window.

https://youtu.be/zQGbKIJknPQ

  Oct 11, 2023     Section 38 - Canopy and Window 10 - (5.5 hours)       Category: Sec 38 CAW

I finished the forward structure. followed instructions exactly and checked for alignment every 4th rivet. I ended up with a perfectly aligned structure. the edges of the forward structure are aligned within 0.1 degree. Very glad with the results.

After finishing the structure, I realized that there was a conflict in the structure with 3 of my "sub-panels" which required some cutouts. But it looks good and solid. Then, I moved on to installing the side rails. I found out that I had to re-do the machine countersinking because the initial pass was too shallow and the skins were not sitting perfectly.

https://youtu.be/ASY9QGEQbpA

  Oct 10, 2023     Section 38 - Canopy and Window 9 - WITH HELPER - (3 hours)       Category: Sec 38 CAW

Another workday with my buddy and we've made good progress on the canopy structure. We finished dimpling all skins, assembled the aft canopy frame, and side rails, and started the forward section. In the forward section, we finished riveting the forward 2 structures. In the forward structure riveting process, I let the bucking bar slip and a small dent was made on the skin. I decided to fix that by adding a hole and rivet to it. Looks like it was supposed to be there but it is not structurally functional. (pics 405.11 and 405.12)

Thanks for the great help and company Kobi!

https://youtu.be/nmQ9dbsLgFI

  Oct 09, 2023     Section 38 - Canopy and Window 8 - WITH HELPER - (4 hours)       Category: Sec 38 CAW

I was lucky to have my friend Kobi over this weekend, and we did great work together. He is a fast learner and quickly got the gist of it. Together we started the assembly of the canopy side rail. Each of us, working on different sides, resulted in a fast pace and fun :)

This step requires a lot of clecoing, unclecoing, match drilling, deburring, and a lot of checks to see if the parts align with the canopy deck. We also deviated from standard plans when it came to the canopy handle. We installed a MOD handle. Very nice finish but requires a different attachment process. instead of rivets, #6 screws are to be installed. Pretty straightforward and the only change is that we will be closing the original rivet holes that won't be used now.

After working on the side rails, we disassembled all parts and, while I was cleaning the parts, Kobi was working on the canopy internal handle and aft structure. He quickly put together the handle, riveting the necessary spots, and headed to the aft structure. While assembling the aft structure we stumbled into a concern. the halves do not perfectly match the inner edges and despite we have installed the template brace and clecoed parts in place, as per instructions, it visually looks like there is something off. Today we will test fit the aft structure in the canopy deck together with the side rails to see if this is all good, the way it is. Hopefully yes.

Thank Kobi for coming over, helping with the project, and spending some good friend time together! :)

https://youtu.be/X9oCe1U_0wM

  Oct 06, 2023     Section 38 - Canopy and Window 7 - (1.8 hours)       Category: Sec 38 CAW

Continued assembling the canopy structure.

https://youtu.be/Zl5ocVuAJgo

  Oct 05, 2023     Section 38 - Canopy and Window 6 - (3.6 hours)       Category: Sec 38 CAW

Back to canopy and window assembly: In this work session I started the assembly of the front portion of the canopy. I missed the metalworking. :)
The structure is coming along very easily and looking very good. A lot of match drilling final drilling and a lot of focus is required to keep the structure aligned to avoid torsions.

https://youtu.be/4BkCUPui_Yg

  Sep 29, 2023     Section 38 - Canopy and Window 5 - (2.3 hours)       Category: Sec 38 CAW

Cleaning and priming canopy parts.

400ml of primer used.

https://youtu.be/kJlhOxesTWI

  Sep 28, 2023     Section 38 - Canopy and Window 4 - (4.2 hours)       Category: Sec 38 CAW

I started the day by assembling the canopy structure just to have a general idea of how the parts would fit together and to map which parts would be primed, naked, and painted.

The next step was to wash all parts in preparation for the priming session.

https://youtu.be/bzEDIvMUSTM

  Sep 27, 2023     Section 38 - Canopy and Window 3 - (2.1 hours)       Category: Sec 38 CAW

Finished deburring all parts for this section.

https://youtu.be/aBpUmDZpXtM

  Sep 26, 2023     Section 38 - Canopy and Window 2 - (6.1 hours)       Category: Sec 38 CAW

Mega boring session. Deburring the world. :)

https://youtu.be/vdi5d9Ii6Jg

  Sep 25, 2023     Section 38 - Canopy and Window 1 - (2.7 hours)       Category: Sec 38 CAW

I started the preparation of the parts for Section 38. Unwrapping and deburring. This will be the last major batch of metal parts and metalworking.

Don't worry Kobi, I will wait for you to actually install it :D

https://youtu.be/lWY1T2rt3rw