Thanks Scott, great informative write-up.
As I read along, I kept hoping for the big surprise that the filler material would in fact become transparent. I wonder if there is a product that would be more clear?
One question I have on your Sikaflex installation. One variable in various people's use is how thick a layer of Sikaflex they create between the frame and the canopy acrylic. I used garden-hose spacers that created a gap of almost 3/16" that got filled with Sikaflex. The hope was/is that this would provide enough expansion flexibility to allow the canopy to grow or shrink without (or with less) stress.
So-how thick is your Sikaflex layer between the frame and canopy?
"The Magic Carpet"
Hobbs 515 in 9 years (would have flown more this year if not for fire smoke)
also LS-6-15/18 sailplane
VAF donation Dec 2017