Started off by re-installing the lexan into position. Cleco'd the sides into position using existing holes. Marked the location of the holes that will be drilled to secure the lexan to the bow. Clamped the rear bow into the 60 deg position. Measured 5/16" forward of the aft edge of the lexan. Drilled 3/32" pilot holes and used long-reach cleco's to hold it all in position. Updrilled to 1/8"; again, used long-reach cleco's to hold into position.
Installed nuts for the AN525 screws holding the windscreen bow to the fuselage sides and torqued to spec.
Drilled the fwd edge of the lexan where it will abut the cowling. Other builders have added additional screws on this edge to reduce waviness of the lexan. Didn't think I would have to, but today it just seemed loose. Added 4 additional holes thru the lexan and upper firewall bow.
Back to the aft edge, I inserted the bow strap between the lexan and the bow itself, which will serve as a resting surface for the canopy. Drilled thru the lexan to mark the spot for the bow. Removed and finished drilling. Reinstalled to check the fit.
Up-drilled the solid aluminum windscreen bow holes to #29 in order to tap them for #8 screws.
Tapped one hole just fine; on the 2nd hole the tap broke of completely flush with the hole. I thought I was going to seriously mangle the hole getting it out, due to the extreme hardness of the carbide taps. Was able to use a very pointed carbide Dremel bit to get a hole started in the tap, which then allowed a drill bit to chip away at it. Fortunately, only about 5/32" of the tap was in the hole, so I didn't take too much. Eventually by alternating the dremel bit and the 3/32" drill bit I was able to get all the way thru the tap. Used a 1/8" punch from the back side and drove out the remaining tap material. The hole was not enlarged, so I was able to continue tapping without incident. Tapped remaining holes just fine.
Initial Pilot Holes
Drilled holes in fwd edge; added 4 additional holes
