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Old December 10th 15, 05:00 AM posted to rec.aviation.soaring
bumper[_4_]
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Default Double-wall Canopy mod to eliminate frost

I have made several clear vision panels.

The last one in two parts for an Arcus. No double sticky tape is used. The edges are sealed with silicone foam weatherstrip (cheaper weatherstrip can be used, but silicone weathers exceptionally well and has a broad temperature range). Panels are of polycarbonate (Lexan) and are held in place by their own tension.

Paper templates are fitted, taped in place first, then removed and using to cut the Lexan slightly oversize. Temporary pieces of cheap weatherstrip are stuck on for spacing and the panel is fitted, trimmed, fitted, repeat ad nauseum. Best to tape the canopy frame to protect if from scraping from all the fitting.

The clear vision panel will be under considerable tension to provide some compression to the silicone foam, thus the sides cannot rest on anything other than the canopy frame (i.e. it can't rest on the sliding window rail. Small leaks are okay, but generally the fit should be snug.

Depending on the glider, some have only a small amount of forward vision space above the glare shield, no forward panel may be needed. But if a vertical panel above the glare shield is desired, it should be acrylic rather than Lexan. Acrylic is better for this application as it is more optically clear and scratches can be polished out (not so with Lexan). Tabs can be added at the bottom, then heat bent to fasten to the underside of the glare shield lip. A small clearance space is desirable at the top of this panel so it does not contact the canopy and to allow the forward vent to flow at least some air around it.

As Dale mentioned, depending on the amount of compound curve of the canopy, head room will be lost with larger clear vision panels, so that's a consideration in the design. Using several strips, still spanning from one canopy rail to the other, so as to fit under tension, would be easier than one or two larger sections.

Nice thing about Lexan is it can be worked with woodworking tools. Can be cold or hot bent, is much more mechanically strong than acrylic, so cracking isn't a problem when cutting, drilling , sanding with belt or Dremel.

But - - even more than some projects, takes at least twice the labor as any reasonable estimate.

bumper