Other Stuff-NEW!
7/2/2008
Tonight was an unexpected work night. It looks like Wednesday's for the rest of the summer will be garage nights...Brit signed up for an Agility class for both dogs an hour north of here, so I have middle of the week work session now!
I began by positioning the rear window exactly where I wanted it using the forward section to line it up. Once I had it in position, I lifted the canopy, and clamped the rear glass in place.
Starting at the back, I drilled the first two holes, and inserted cleco's.
After about an hour, I had all the holes drilled using the plans recommended zigzag pattern. Left, right at the back, then left, right at the roll bar, starting at the top and working down.
I just had to lower the canopy to check the fit between the two pieces...
Fits GREAT! I have about a 3/32" gap all the way around.
After this I removed the rear glass to deburr the holes in the plexi and the skin/roll bar. I then drilled the roll bar holes to 7/64. The plans say to use a #35 bit, but I don't have one (and forgot to grab one at work). 7/64 is .0006 smaller than a #35, so the holes will still thread just fine.
After that I drilled the holes in the aft skin to #27, and drilled the holes in the rear window out to #27 and deburred them. These will get countersunk, then drilled out again to 5/32.
2.5 hours