My Finish Kit for my RV-9a slider arrives tomorrow. I fear the canopy process, I will admit.
Some basic questions that I don't seem to be able to get clear on:
1. I purchased standard sized plexi bits (1/8, 5/32, 3/16, 1/4) from Cleaveland Tool, but instructions say to pilot drill through the canopy into the frame tubes with a #40 bit. Do they mean a plexi #40? They just say "#40" and that the holes in the canopy will be later enlarged with a 5/32 plexi bit. If so, why am I not worried about cracking with the #40 through the plexi and into the frame? Won't a #40 plexi bit cut into the frame tubes and avoid cracking potential? Why not use one of those then? I am obviously confused here.
2. What tools are used to deburr these holes and freshly cut edges and in what sequence? They mention filling, but files can cause cracking I would guess. The holes are too small for a file anyway it would seem. Perhaps I am to use my deburring bit on the holes (as I would on aluminum) and a super fine file on the edges, followed by 200, then 400 grit paper? Won't my deburring tool be rather risky on plexiglass?
3. Am I to use my deburring tool to counter sink these plexiglass holes as well, or my #40 micro sink (which seems a little scary).
Needless to say, I am scared to death! I would abandon drilling completely and use the SikaFlex process, but I am a disaster with glues. My fuel tanks look like they were in a war.....but they don't leak!
Any advice will be much appreciated.
Some basic questions that I don't seem to be able to get clear on:
1. I purchased standard sized plexi bits (1/8, 5/32, 3/16, 1/4) from Cleaveland Tool, but instructions say to pilot drill through the canopy into the frame tubes with a #40 bit. Do they mean a plexi #40? They just say "#40" and that the holes in the canopy will be later enlarged with a 5/32 plexi bit. If so, why am I not worried about cracking with the #40 through the plexi and into the frame? Won't a #40 plexi bit cut into the frame tubes and avoid cracking potential? Why not use one of those then? I am obviously confused here.
2. What tools are used to deburr these holes and freshly cut edges and in what sequence? They mention filling, but files can cause cracking I would guess. The holes are too small for a file anyway it would seem. Perhaps I am to use my deburring bit on the holes (as I would on aluminum) and a super fine file on the edges, followed by 200, then 400 grit paper? Won't my deburring tool be rather risky on plexiglass?
3. Am I to use my deburring tool to counter sink these plexiglass holes as well, or my #40 micro sink (which seems a little scary).
Needless to say, I am scared to death! I would abandon drilling completely and use the SikaFlex process, but I am a disaster with glues. My fuel tanks look like they were in a war.....but they don't leak!
Any advice will be much appreciated.