Chapter 18 – Canopy

Chapter 18 – Canopy

13 January 2013 — I took the opportunity while in Florida to pick up my canopy from Todd Silver in Ft. Lauderdale (there’s a lot of forts in Florida, eh?).  Todd’s a good guy!

My Canopy

Chap 18 - Canopy

Here’s somewhat of a representation how this canopy style will look:

Canopy Style

•••

30 May 2013 — I had to run out & deliver some items I’ve sold online in prep for my move. Since it was in the latter part of the evening when I got started, I focused on planning out some details on what I call the “D-Deck,” the area at the aft end of the cabin, behind the GIB’s head, on top of the CS spar, and just forward of the firewall.  Basically the rear passenger’s head rest area.  I would like to build my canopy frame so that the frame continues past the aft edge of the canopy glass significantly farther than stock & have it intersect the firewall in much the same way as Wayne Blackler did on his Long-EZ:

Wayne Blackler's Long-EZWayne Blacklers Long-EZ

To me, this removes the cavernous area behind the GIB’s head, provides a headrest platform, and an area to hide away electronics (and the fuel tank vent manifold).  Since I’ll be using GRT’s Engine Information System (GRT EIS-4000) I’d like to mount the EIS control unit in the D-Deck electronics area much like Nick Ugolini did (shown below, but without the spare battery) and as he discusses on his blog:

Nick Ugolini's GRT EIS Installation

I’ll be honest, at first I didn’t like the thought of putting the EIS control head back in the aft of the aircraft.  I didn’t really see the light until I spoke with a GRT rep at the Sebring LSA show and he asked me why I would want to mount it up front in a Long-EZ with all that engine probe wiring traversing a good total length of the fuselage (i.e. bad for space, current noise & WEIGHT).  The GRT EIS control unit can really get away with one single wire feeding the EFIS all the engine info that is processed, tracked & displayed (which is a lot!).  If one wants to be able to upgrade the unit at the front panel with a laptop connection, then they would require a whole ‘nother whopping second wire (vs. Lord knows how many by bringing all the probes up to the instrument panel). Thus, I get a well deserved “DUH!” on that one.  Ok, GRT (and Nick) ya’ got me this time, but never again . . . ha!

I started measuring, designing and crafting my D-Deck electronics/fuel vent manifold housing.

•••

1-4 June 2013 — I finished my D-deck mock-up & then made some cardboard and duct tape mock ups of the Electroair Electronic Ignition controller.  I placed the Electroair controller into the D-deck mock-up along with the fuel tank vent manifold and just the face-plate cutout of the GRT EIS-4000 control unit to see if there would be enough space.  As you can tell, it looks like there will be plenty of room.

Chapter 18 - D-deck mockupChapter 18 - D-deck mockup

•••

28 October 2014 — I’ve been talking with Todd Silver for a number of months now on getting a new canopy.

Why?  Well, here’s the story:
The first canopy I got from Todd was one that I went down and picked up out of his shop in Ft. Lauderdale in early 2013 while I was deployed to Tampa, FL.  I had wanted a little bit larger/longer canopy so that I wouldn’t have the windscreen up so close to my face, and a little bit taller to have just a little bit more “cabin” space.  However, I should have analyzed the shape of the canopy more thoroughly before throwing it in the back of my vehicle and hauling it back up to Tampa.

Fast-forward to late 2013, once I was settled into my job in Qatar, where I had more time to ponder various build aspects since I wasn’t actually making layups or sniffing epoxy fumes.  I took my pics of the canopy, traced them out (poor man’s CAD) and then overlaid them onto an outline of a close depiction of my fuselage.  I checked this out a number of times from as many angles as I could find.  The main depiction of what I found is here:

Old CanopyThe canopy profile is very close to a true section of a circle on a standard curve. What this meant is the highest point of the canopy sat behind the rollover structure and really wasn’t adding any usable space, but was most certainly adding drag.  Now, to be clear I picked this canopy out of a lineup and the result of my dissatisfaction with it was my fault, not Todd’s.  Todd was nothing but exceptionally helpful as I was looking at his canopies.  In addition, the shape of the canopy also meant a fairly flat and low profile directly in front of the pilot’s seat, and a sharper curve aft where the canopy met the firewall structure.  To be clear on another point: this canopy is beautiful.  It just happened to have the wrong characteristics that I was looking for.

Now, I confirmed my misgivings with the canopy when I came back to the states for a couple of weeks from Qatar in March 2014.  I hauled the canopy down to my buddy Marco’s shop (since my project–but obviously not my canopy–was in storage) and we trial fitted it on his fuselage.  Now, I widened my fuselage 1.4 inches at the pilot seat, but the rest of the fuselage is widened at the same ratio as the original plans fuselage (except my firewall).  Being more of a maverick, Marco chose to widen his fuselage 2 inches the entire length.  When we put the canopy on his fuselage it displayed and confirmed the characteristics I was concerned about (see pic above), but it also proved to me that the dimensions were just too big, since the canopy was close to being oversized even for Marco’s bigger fuselage.

With confirmation in hand, I approached Todd and let him know my concerns.  I sent him the pic above along with this pic below depicting more of the shape I was looking for (BTW, I used Steve Volovsek’s canopy as a style reference).

Desired Canopy

As you can see, the most “bubbly”part of the canopy is directly over the pilot as it flattens out behind the pilot for a good intersection angle with the firewall.

Thus began a conversation over the next few months about the size, shape, etc. of the canopy I was wanting.  Since I wasn’t in a hurry to get a new canopy until after I got back from overseas and settled in, Todd and I waited until I got back to finalize my choice of a new canopy.  Well once back, Todd of course delivered in spades.  He sent me a lineup of pics of a few different canopies (I think knowing full well which one I’d pick) that were all very close to what I wanted, with one being spot on:

New Canopy

Compared to my existing canopy on-hand:

My CanopyTodd was a champ and gave me a great deal even though I was the one who initially picked the “wrong” canopy.  Once I picked out my new canopy he shipped it out the same day.

[Note: I have since sold my first canopy to Chris Seats.  Apparently he’s a more bubbly guy than I am . . . ha!]

•••

5 November 2014 — Today I went down to a freight terminal 40 miles south of my house to pick up my new canopy that Todd Silver sent out last week.  Todd had shipped out the canopy in hopes of getting a look a the canopy mocked up on my fuselage when he stopped through town as part of his multi-state canopy install tour that he was on.  Unfortunately for Todd, he stopped by on Tuesday evening (last night), but since I had originally received an estimated delivery for Wednesday (today), that’s when I picked up the canopy.

New Canopy

Canopy - SecuredCanopy - with plate!Canopy Overhead Shot

Here’s a shot of the new canopy that Todd had hoped to see!

New Canopy Profile

As you can see by the pic above, the new canopy’s profile is excellent and the dimensions are spot on.  I am VERY happy with this canopy!

•••

20 August 2016 — During the last week I have been doing some odd & end stuff on the build, much of it stuff I was never able to really put together before since I didn’t have all the pieces parts in the same location.

A note that I’ve had for a while in the middle of my electrical switch diagram states to account for the panel space required by the canopy latch arm that sticks out horizontally into the space near the throttle handle.  I became acutely aware of how much space the canopy latch was really taking up when I sat in my buddy Marco’s Long-EZ specifically to note clearances, required reach to cockpit items/switches, and simple ergonomics.  It emphasized that the note on my switch diagram truly had merit, and that I must indeed account for this most necessary but intrusive component (pic below is from Jack’s website).

EZ-Rotary Canopy Latch

Thus, back at my hacienda, I finally got around to pulling out the EZ-Rotary Canopy Latch kit that I bought from Jack Wilhelmson (eznoselift.com).  I first (re-)inventoried all the parts to ensure I hadn’t lost anything over the years.  I then did a quick (re-)review of the installation procedures to get a feel of what I was up against.   My main current concern was of course the clearance with the instrument panel, and luckily with this setup the bearing block hangs down from underneath the longeron, and not straight out from the panel, thus giving me back the 3-4 square inches that I wouldn’t have been able to use on my instrument panel if I had installed the plans version of the canopy latch.

•••

23 February 2017 — When I spoke with Rich at Aircraft Extras about adding new AG6 warning screens (shown below) to a couple of new chips for me, I added a bottle of canopy cleaner and a tire air nozzle extension to the order to optimize shipping costs.

Aircraft Extras order

•••

26 June 2017 — I realized as I was making up a quick sketch of all the GIB controlled electrical components (with the addition of the LED lit fuel site gauges) that I should account for the canopy locking rod & latches.  I stumbled upon a discovery that shows yet another faulty assumption on my part, and I’m not sure exactly how I missed it.

The bottom line is that I found that the midpoint canopy latch is supposed to be –as per plans– situated at the front business area of my roll bar.  I played around with it for a while, but realized I just had to bite the bullet and will have to move the middle canopy latch about 1.4″ forward.  I’ll probably adjust the aft latch a hair forward as well, but at least now I know.  Amazing that just this nth order affect took me about an hour to track down (well, technically over 2 years to track down!).

•••

28 August 2017 — Today, after reviewing a bunch of pics I took of Marco’s firewall and engine compartment, and researching a bit while looking at some other folks’ firewalls, I then reworked the component diagram I have for my firewall.  May seem a bit ahead of the game, but if all goes right I will be mounting the firewall to the fuselage for good here in the next few weeks, and I wanted to figure out internal hell hole (aka “firewall forward”) component placement.

Moreover, as I install the canopy I will construct a GIB headrest assembly that will also be a compartment containing the GRT EIS4000 engine management control head and the Electroair Electronic Ignition controller as well.  Having a good idea for where & how these component wires transit the firewall is a good thing.

•••

2 September 2017 — Today Chris Seats was going to come up from Fredericksburg, VA to pick up my extra canopy that he’s buying from me, and to take a look at my Long-EZ build.  I finished up some errands and was about an hour into straightening up the shop when I got a message from him saying that traffic was way backed up and it was going to take him twice as long as usual to get here, so understandably Chris rescheduled his visit.  If any of you know DC area traffic, it can be brutal at times.

So, I worked a bit more on getting my shop squared away when out of curiosity I checked the traffic situation from my side down.  Interestingly, if I went down to see him it was going to taking half the time than him coming north.  After conferring with Chris, I loaded up the Todd Silver made canopy and hauled it down to Chris’s shop in Fredericksburg.

I got there around 1530 and planned on leaving an hour or two later.  Well, by the time I got out of there . . . of course talking all things Long-EZ, it was nearly 2100.  I got some great ideas and some really good insight into some common engine components that we both have.

•••

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Project Update

Hi Folks,

Well, Rough River 2017 is in the history books.  A great Rough River all the way around!  Marco’s new GRT Mini & GNRS480 avionics install went off without a hitch, providing an awesome proof of concept for my upcoming panel.  In addition, the myriad of builder tips that I got from Buly, Rick Hall, James Redmon, Terry Schubert, Mike Beasley, Bruce Sinclair, Bill James and countless others were gold in the bank for so many upcoming component decisions and configurations I need to make.

As I mentioned before, I’ve had to adjust my schedule a bit over the past 6 weeks, which of course impacts my goals.  Yes, I will continue to fight in my hope that this will be the final push to get the main assembly of the aircraft completed.   I do plan on having the main structure of the aircraft finished by year’s end.  An aggressive timeline to be sure, but I think it’s very doable.

I’m still working out the finer details of making everything fit inside the cockpit.  Since the vast majority of what I’m doing are all mods, these usually require a lot of in-house R&D, and then trial & error when finally at the install phase.  However, the curve is exponential in that as each component is designed and installed, it accelerates the build because besides just being in the “done” column, it is one less thing to design and build.  Moreover, it’s a variable that has been changed into a constant.

All this is just to say that even though things seem to be going slowly, there really is a momentum building for this project.  These pesky mini-tasks burn time, but as they are finished and systems are integrated, then when the final airframe components builds are finished, this plane will seriously be close to being done. Again, these mini-tasks are definitely time-consuming and a lot more slow going then planned.  But finishing them now allows me to work all this stuff while I can stand right next to the fuselage without having to deal with strakes, or nose, being in the way!  

I have to say that it’s much easier and more fun to build the big stuff that makes this project look like a plane, and I often feel my discipline waining to go build something “cool”.  So, although obviously not as sexy as seeing major aircraft components (i.e. nose, strakes, canopy) being completed, these mini-tasks are oh so necessary for quality of flying later on!  Moreover, these immediate tasks, in turn, will allow me to finalize the configuration of the nose components. At which point I will focus on the building the nose and the canopy.  . . while concurrently finalizing the wheel pants install (nope, haven’t forgot about those!).

Cheers!

 

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