Jur's RV7 Aircraft Factory
2917 hours and counting
Some decisions in life are bare of any obvious logic

 Some more messing around with the rollbar. Tried in multiple attempts to get the small twist out of the roll bar but without heavy machinery this is not possible.

Overall the position is good but as you see in the image below, the pilot side foot sits high on the front.

I used a fishing line wire between the two vertical posts of the roll bar and hung some plumb bobs on 3 locations over the top of the roll bar. This is the best way to check the 90 degree square on the canopy deck. Holding a square against the vertical posts is not accurate enough as the weldings sit in the way.

Update Dec 2020: After leveling out and squaring the roll bar, it showed that actually the pilot side has to sit flat which makes the passenger side front to stick up a bit. I will make a spacer on the passenger front side to fill the gap.

Finalised drilling pilot side of the roll bar using the same technique with the drill hole duplicator.

Double checking the 7/32 spacing between the side of the F-721B-L canopy deck and the WD-641 roll bar.

It has been a long time since there was a "Make From" moment in the plans but today was part making day again.

You have to make some spacers or clamps that hold the rollbar clamped behind the longeron.

Gently grind down the inside and round the corners to that the spacers fit nicely within the longeron corner on the outside and the canopy bend on the inside.
Then draw centerlines on the spacer so that you can fit and matchdrill through the already drilled holes in the canopy decks. I "start drilled" them and finished it off on the bench drill.
The canopy decks are too thin and the risk is too high to wander in the predrilled holes to fully drill them on the plane.
Don't forget there are two sizes  for and AN4 and AN3 bolt.

Here is the result of the drilling. Mark the pilot and passenger side

I did not like the idea of drilling from the bottom through the pilot hole through the still foot of the roll bar. Same worries here on enlaring the holes in the canopy deck.
I found the method illustrated in the image below a better practice. These are still pilot holes #40. I used the hole duplicator, then clamped the roll bar in place and drilled from the top. This worked out perfectly.

The roll bar has to sit in a location measured from a rivet on the fuselage side skin.

The side of the rollbar has to be 7/32 off the edge of the side skin (canopy deck outer edge).

Same trick with the duplicator on the front side. At same time ensuring the distance from the edge.

After drilling clecoed the roll bar to the canopy deck and re-checked spacing.

Up drilled to #30 t from the top through the base of the roll bar.

Same exercise on the passenger side checking the spacing from the outer edge.

Started construction of the side rails. The front of the canopy frame is supported by 2 rollers which slide into the bottom of the canopy frame.

When everything is lined up, you drill through the frame and the roller assembly which locks the rollers in place.

However, this can only be done late in the process as the height of the canopy frame  is determined much later after the canopy drilling to the frame. So for now you just make the roller assemblies and insert them in the bottom of the canopy frame tubes. You can use some clamps to put pressure and clamp them in place.

Before continuing, I wanted to re-measure the 90° angle on the roll bar. First I checked if the fuselage was sitting level. 0.1 very very  close.

Then attached fishing wire across the roll bar verticals and hun some plumb bobs over the top. The distance between the vertical fish lines of the plumb bobs to the reference line across the verticals shows you how close the angle is to 90 degrees. It takes some patience but it's the perfect way to check.

Then started measuring the canopy track rails. Made one and then copied the length on the second.

Clamped them together and drilled the hole pattern in the horizontal part to #40. These are pilot holes which will be matchdrilled to the canopy decks once the final fitting of the canopy frame is completed.

 I clamped them temporarily in place to test out the fit of the frame. So do not drill now, the whole practice of bending the canopy frame will lead to the exact position for these rails. You can only drill when the canopy frame has it's final shape.