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ed.kettler
Joined: 27 Oct 2018
Posts: 18
Location: Fort Worth TX
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 Posted: Tue Jan 29, 2019 6:51 am Post subject: CJ Malcolm Hood |
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I am planning to replace the canopy on my CJ with a Malcolm Hood, and I am looking for best practices so that I can avoid cracking and minimize frustrations.
I have read somewhere that the fastener holes need to be larger than the fastener, but not how much.
Do you drill pilot holes first, then final holes?
I know that I should be in a warm environment to drill, but what is the recommended temperature range?
Do you start at the top, then work to the sides? What about front to back?
Any special drill bits?
Trimming the plexiglass ... cutoff wheel?
Any other hard won words of wisdom?
Many thanks!
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Ed Kettler
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A35plt
Joined: 14 Aug 2013
Posts: 9
Location: Wiesbaden, Germany
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| Posted: Sat Apr 27, 2019 8:43 am Post subject: Re: CJ Malcolm Hood |
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I have read somewhere that the fastener holes need to be larger than the fastener, but not how much.
Yes, a good rule of thumb is 1/2 the diameter of the bolt.
Do you drill pilot holes first, then final holes?
Yes. use clecos to assemble the canopy and mark your final cuts and drills with a sharpie.
I know that I should be in a warm environment to drill, but what is the recommended temperature range?
At least 70 degrees, warmer is better. If you can get it warm enough so that you are warm but no sweating (at) 85 degrees I have found to be best in my work shop. Don't forget that having the canopy in a warm area for a few hours at least is best. i.e. Don't bring your freezing cold canopy in the shop where it's 80 degrees and then start working it it will crack!!
Do you start at the top, then work to the sides? What about front to back?
I always started at the top because the screws on the top of the bow were the most difficult to line up, then skip 2 holes and do another, again use clecos and clamps , work your way all around then come back and fill in. this way you hopefully don't have more stress / tightness on one part of the canopy than aother which can lead to warping and misalignment issues.
Any special drill bits?
Yes you want the Plexiglass drill bits, but more than you need so you are always using a sharp one. Sold at aircraft spruce or maybe even your local hardware store.
Trimming the plexiglass ... cutoff wheel?
Yes use a brown composite cut off wheel. Go slow and let the tool do the work. Having a helper hold a shop vac next to the work will do wonders for minimizing debris and mess that can cause problems later. Wear hearing protection.
Any other hard won words of wisdom?
If you use a sealant around the edges of your frame to keep water out, do not embed the glass into the frame with the sealant. That could make it impossible to remove later if the canopy cracks and needs replacement.
Also, make a simple fixture to hold your canopy frame square during your work. Only takes a second but is very handy during reassembly. Use clean carpet pads or thick blankets in the shop to protect surfaces from being scratched. If your canopy does not come covered with a protective paper cover consider covering the majority of the canopy with contact paper to protect it.
Hope this helps some... Good Luck, Go slow and it will turn out great!
-Robert Starnes
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