Another post covering the last couple of days on the plane build, still focusing on the canopy latch system.

My primary focus starting out was to ensure that I could redesign the GIB cockpit light master power switch box which also contains a spare switch for any future switch requirement (why not, eh?).

Instead of mounting the switches’ long flat sides up-and-down against the sidewall (inside the box), I turned them 90° so the thin side was parallel the sidewall and the long side was underneath the bottom of the longeron.  On the 2nd or 3rd iteration of this new design, I angled the thin sides of the box inward a bit to give the switches a bit of an angle (to better get my finger behind the switch paddle when against sidewall).

I then checked the new GIB lights switch box clearance with the position of the canopy latch rod as it was straight and level from the aft end (equidistant from longeron all the way down its full length).  Not outstanding, but definitely within the normal tight tolerances on these Long-EZs!

I then checked the clearance of the canopy latch rod and the SC-1 canopy safety catch… again, close but definitely workable with the rod under the longeron…

Speaking of which, here’s a shot of that forward canopy latch rod tucked up underneath the longeron its full length.

In my testing and manipulations of the canopy handle with my 3D-printed test aft push-pull handle rod installed, I stressed it a bit too much and it cracked.  I did get some good operational data from these tests, and even it cracking gave me an idea of where the stress points were.

I then re-3D printed the canopy handle aft push-pull rod with a lot higher infill % to make it stronger, and also cut the rod-end to C4 bracket bolt slip sleeve spacer to connect the handle to the canopy hook manipulating rods.

Here we have the new test set up with the handle open (pic 1) and closed (pic 2).

I’ll also make a special note that with the remaking of the canopy handle center block, the forward push-pull rod can now traverse much farther aft inside the handle bracket channel.

And here we have yet another check with the SC-1 canopy safety catch, with all clearances still good!

I then got to work on making a new canopy handle aft push-pull rod.  I started by chucking up the 5/16″ diameter 2024 aluminum rod in the lathe and narrowing down the threaded end to a little under 0.250″ (pic 1), after which I used a 1/4-28 die to create threads on the narrowed rod segment (pic 2).

Here we have the 1/4-28 threads created on the 2024 aluminum canopy handle aft push-pull rod.

Of course an ‘operational’ test fit of the rod-end was required… and all looked good.

I then cut the 5/16″ diameter 2024 aluminum canopy handle aft push-pull rod on the horizontal bandsaw (pic 1).  And here’s a shot of the real aluminum canopy handle aft push-pull rod with its 3D printed twin (pic 2).

I then fired up the mill to machine the opposite end to create the flat that will get secured into the canopy handle forward push-pull rod.

And Voila!  The freshly created 2024 aluminum canopy handle aft push-pull rod.

I then installed the newly made canopy handle aft push-pull rod into the canopy latch handle, at which point I climbed inside the cockpit to test it out.  After a few rounds of tweaks I am pretty darn sure that I am VERY close to dialing this canopy latch handle in so that it is 100% operational.  The aft throw is very acceptable and the latching pressure needs some tweaking (appears to be easily remedied), while the over-center action is VERY noticeably improved.

I’m heading out of town for a quick 2-day getaway with Jess, but when I return I plan on finalizing this canopy latch handle operational configuration.

Pressing forward!