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Old 01-11-2018, 12:26 AM
Scott Chastain's Avatar
Scott Chastain Scott Chastain is offline
Join Date: Jan 2005
Location: KMCE
Posts: 52
Default The Unhappy Cracky Club

How long, O Lord? Will you forget me forever?
How long will you hide your face from me?
How long shall I take counsel in my soul,
Having sorrow in my heart daily?
How long will my enemy be exalted over me?

Consider and hear me, O Lord my God;
Enlighten my eyes,
Lest I sleep the sleep of death;
Lest my enemy say, "I have prevailed against him";
Lest those who trouble me rejoice when I am moved.

But I have trusted in your mercy;
My heart shall rejoice in your salvation.
I will sing to the Lord,
Because he has dealt bountifully with me.

Psalm 13
Scott Chastain
RV-8 N898W Descending Dove

Last edited by Scott Chastain : 08-26-2018 at 10:54 PM.
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Old 01-11-2018, 07:17 AM
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wjb wjb is offline
Join Date: Nov 2012
Location: Half Moon Bay, CA
Posts: 781

Great writeup Scott! All the minute detail is very informative. Looking forward to hearing how it stands up for your next 40 day cross-country trip!
Bill Bencze
N430WB (reserved) RV-7 #74152, tip-up. Working the baffles
Log at:
Defeating gravity one rivet at a time
VAF 2018 donation happily made
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Old 01-11-2018, 07:29 AM
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9GT 9GT is offline
Join Date: Jan 2010
Location: Southern Michigan
Posts: 1,477

Fantastic write-up and documentation of your repair Scott! A post that will get referenced and studied for years to come I am sure.
David C.
Howell, MI

RV-9A: Under Construction. N161RV (Reserved)
RV-10: N959RV Completed 12/29/2013 SOLD 08/23/2016

"Donor Exempt" but donated through Dec. 2018
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Old 01-11-2018, 07:29 AM
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Saber25 Saber25 is offline
Join Date: Dec 2010
Location: Colorado
Posts: 184

Excellent repair description and helpful pictures. How many labor hours involved?

Every time I look at my 30 year old canopy I knock on was possibly the most difficult part of the construction.

Cheers, Hans
Build 'em light, keep it simple

I'd rather fly than tinker.

"There's a big difference between a pilot and an aviator. One is a technician, the other is an artist in love with flight."
- Elrey B. Jeppesen,
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Old 01-11-2018, 12:15 PM
Canadian_JOY Canadian_JOY is offline
Join Date: Aug 2007
Location: Ontario, Canada
Posts: 1,748

Great write-up indeed. I didn't know the Plasti-Fix product existed. Good to know.

Given the highly hazardous abrasive application process you used, I'm glad to see you had canine supervision to ensure you did it right! :-)
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Old 01-11-2018, 01:10 PM
Bevan Bevan is offline
Join Date: Sep 2007
Location: BC
Posts: 1,553

Excellent workmanship, and result write-up. Thanks for documenting it for should it be needed in the future.

RV7A Flying
O-360-A1F6 (parallel valve) 180HP
Dual P-mags
Precision F.I. with AP purge valve
Vinyl Wrapped Exterior
Grand Rapids EFIS
Located in western Canada
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Old 01-11-2018, 01:21 PM
jklusman jklusman is offline
Join Date: Feb 2013
Location: Lafayette, IN
Posts: 7

Thanks for the super documentation, Scott. The canopy on my RV-8 has a 5-inch crack in almost the same location. It has been stop-drilled twice and seems to be stabilized. This canopy was installed using machine screws. I didn't build the aircraft, and when I bought it, the crack to the first stop-drill was covered with a decal. After the crack extension, probably caused by temps near zero in the hanger, I paid more attention to closing the canopy and noticed that latching it caused a slight distortion of the frame to the left. So, I now close the canopy the final 1/4 inch when getting ready for T/O by pushing on both sides of the front frame. Don't know if that will make a difference, but it sure can't hurt. I leave the canopy open 1/2 inch when it's in the hanger. I've bookmarked your page just in case...
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Old 01-11-2018, 07:49 PM
RViter RViter is offline
Join Date: Jun 2009
Location: Mesa, AZ
Posts: 210

Kept expecting a surprise ending - a faux Targa strip painted on the inside/outside of the Plexi that would look like a design feature.

Since I'm not an RV-8 owner the position of such a faux strip and the possibility of simply obscuring visibility is difficult to judge but considering the visual effect, would it otherwise work?

Thanks for the write-up and details of a repair option.
RV-6A QB Tip-Up, 1st Flight 3/18/17
O-360-J2A (modified & F/I), Sensenich FP (cruise)
VP-X Sport, Dynon SkyView, VFR day
(FFZ) Mesa, AZ - N234GB -
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Old 01-11-2018, 09:08 PM
moosepileit moosepileit is offline
Join Date: Dec 2010
Location: Floyds Knobs, IN
Posts: 286

Could make it look like the SMDC in some ejection seat systems.
RV-6 N91GG, bought from builder.
O-320, slider, carb, mags, FP
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Old 01-11-2018, 09:43 PM
Captain Avgas Captain Avgas is offline
Join Date: Oct 2005
Location: Melbourne, Australia
Posts: 1,659

Originally Posted by Scott Chastain View Post
As the polishing progressed, small occlusions became visible along the upper edges of the V-groove.

The cause of the occlusions was unknown. Great care was taken to clean the plastic prior to bonding. Nevertheless, whether or not the imperfections would develop into full-blown cracks was yet to be seen.
Scott, a fascinating and instructive post with great pix. However a couple of questions for you.

Can you tell me why you used the PPG DX330 Acryli-Clean to prep the canopy. My understanding from reading the product tech info is that the DX330 is not suitable for acrylic (despite the name). The PPG SX103 might have been the more appropriate product. Is it possible that the occlusions you developed arose through using the wrong cleaner.

I am surprised that when you were using a Polyvance adhesive (ie Plastifix Clear) you did not use the Polyvance cleaner (1000-A Super Prep Plastic Cleaner) to maintain compatibility.

And finally, the fact that the Plastifix Clear was not in reality clear at all (but translucent) must have been disappointing. Is it possible that a Weldon Product might have been more transparent.
Bob Barrow
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