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RV-9A: Canopy - 8/12/2012
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Time to fit the WD-643-SS Canopy BraceTime to fit the WD-643-SS Canopy Brace
I say "fit" because the canopy brace will receive it's final tightening in place when the forward top skin is riveted on. This was a little bit of head scratcher. After looking at the plans, I determined that the deciding factor in fitting this brace would be the forward most bolt and the gap left for the top skin to go under the brace. I cut and clamped a couple of scrap pieces of aluminum that together would establish the gap needed for the top skin to go under the brace. The gap is a little larger than the actual thickness of the top skin. I drew a line on the flat flange of the brace 3/8 of an inch from the forward edge of the brace flange. This line would show up in the predrilled hole in the aluminum angle previously installed on the panel rib. All I had to do then was "eye-ball" the cut-off mark on the other end of the brace by laying it down on top of the roll-bar.
Cut off the end of the WS-643-SS braceCut off the end of the WS-643-SS brace
I bought a new 34 tooth x 12 inch hack saw blade and cut off the end of the brace according to my eye-ball measurement. I purposely left it about a 32nd long so I could do a custom fit by test fitting it in it's final position and going back and forth to the old grinder.
Drill the holes into the forward flange of the braceDrill the holes into the forward flange of the brace
After getting a good fit on the aft end of the brace on the Roll Bar, I clamped the forward end of the brace in place and drilled the holes using the pre-existing holes in the support angle. Then I temporarily put the bolts in (not tight) to hold the brace in place so I could drill the large in the aft end of the brace on the roll bar.
Drilled the hole into the aft end of the braceDrilled the hole into the aft end of the brace
I started off by marking the place for the bolt hole a half inch from the forward edge of the roll bar attachent flange. I drilled a small hole on each side of the roll bar flange into the brace pipe using a 3/32 bit in my pneumatic angle drill. Then was easy to enlarge the hole to 1/4 inch using the 3/32 inch as a guide.
Thar' tis, as my dear old Dad would say.Thar' tis, as my dear old Dad would say.
Like I said before, I left the bolts loose, since this dude will have to come out for riveting on the forward skin.
What the heck, one more shot...What the heck, one more shot...
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