SonexBuilders.net

Word of caution on tests to see if drilling causes cracks in Plexiglas. The drilling itself rarely results in cracks, but creates conditions where when the material is stressed, cracks will start and propagate.

David A. Sonex TD with Bonded (no holes) canopy.

Nearly done with the canopy:









Quite happy with the result.

As others have done I did not worry about getting the bows positioned 100% right, just made sure during test fitting that they did not push the canopy outward, or were they too far away from the Plexiglas which would not allow installation of the screws.
I then just used nylon washers to compensate for the gap between bow & Plexiglas. In one place I needed no washers but in most I needed 1 or 2.
It is very easy to do this way and the results are great, I have a smooth transition between the windscreen/canopy/turtledeck

Now I just need to remove it once more so I can sand a bit off the aft edge as it is a bit closer to the turtledeck than the required 1/16"
After that I'm done with it.

Looks awesome!

Took the canopy off and did some final sanding to achieve the required 1/16" gap.
Put it back on and removed the protective plastic film.

I'm happy to say I'm now done with the canopy!

During my 5 year build I have pretty much experienced every common issue Sonex builders come accros in their project, like stuffing up the wing rigging etc, plus I'm proud to say I invented a few new ones.
Anyway, after all that I was almost expecting to become a member of the cracked canopy club as well, but I'm very happy do say I didn't! (so far :) )

I actually found the canopy installation not to be that hard, I followed the plans and instructions, apart from the cutting which I did with a Dremel tool & cutoff wheel.
I think it's just a matter of taking it slow and never ever ever trying to force anything (I had to keep repeating this one in my head constantly).

Initially I was planning to install a gas strut instead of using the canopy cable, I had even bought all the parts for that, but I'm at the point now where I just want to be done with it so I stuck to the plans for now, I might still retrofit the gas strut later.

Well, here are some pictures:



Looks cool doesn't it?


One happy camper :D

Very cool!

Awesome to see this! Congratulations!


Robbie Culver
Sonex 1517
Chicagoland
Tails and Wings complete - finishing fuselage.
N1517S reserved

Congrats on a beautiful job!!

Thanks for the kind words guys.

Now lets see,

- V-Tail done
- H-Tail done
- Aft Fuselage done
- Fwd Fuselage done
- Wings done
- Wings rigging done
- Electrical done
- Engine installation done
- Cowling done
- Canopy installation done

Running out of things to do here... :D

rizzz wrote:Thanks for the kind words guys.

Now lets see,

- V-Tail done
- H-Tail done
- Aft Fuselage done
- Fwd Fuselage done
- Wings done
- Wings rigging done
- Electrical done
- Engine installation done
- Cowling done
- Canopy installation done

Running out of things to do here... :D

Huh....I can think of one more.... :-)


Robbie Culver
Sonex 1517
Chicagoland
Tails and Wings complete - finishing fuselage.
N1517S reserved

Hi ya'll,

I'm reviving this old thread to ask a related question: Is it okay to do canopy before cowl? I'll be placing the windscreen as high as possible and it is much easier for me to work on the canopy first for shop space reasons...