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

More finetuning and cutting on the windscreen plexi. I'm getting pretty close now.
The sides are still a bit too much open so I need to do some final trimming to do towards the lower 30 degree position. There is a remaining small gap between the plexi and the fuselage skin on the sides and I'm not sure where to cut next or if it's worth cutting more.

As I was cutting back the sides, the windscreen also had the tendency to warp back making the fit with the slider plexi stand open.
I gently sanded away material from the bottom of the back of the windscreen and tried to keep a straight line as good as possible.

Some more pictures of the position so far. Not bad at all. Only those damned sides still stand out a bit. I think the remaining excess plexi in on the lower side towards the sharp bent in the top skin.

 passenger side

As I'm getting closer, I startd checking the height of windscreen versus slider. Here I'll have to add some nylon washers as shims to bring the windscreen equal or a slight bit higher than the slider for an easy fairing transition.

Same towards the other side. This is actually quite normal to do so I'm pretty sure as it's that subtile differnce in bow between the roll bar and the slider frame front bow.
I'm still on the right track.

Did some more fine tuning on the legs of the front bow to lower the slider a tiny bit.
This kind of things is actually very time consuming. you have to take the plexi of, do some filing and cleco it back on to check the fit and this in a repetitive process.

finally, the trimming and adjusting of the windscreen has come to an end. The sides now nicely fit the sides of the fuselage.
I added painterstape on the rollbar and positioned the windscreen in place for drilling. Used some duct tape to make sure it stayed where it's supposed to be.

Mesaured the distances for the screws. Actually reduced the spacing a bit and added some more screws than required on the plans.

drilled the first hole.You can see the marks the painter tape makes where it touches the plexi.
Important: make sure you angle the drill correctly so it's perpendicular to the plexi. The touching point is sometimes at an angle. If your holes are not perpendicular, you'll end up with problems later after tapping the hole and trying to insert the screw.

Each time marked the location of the mark.

then used the same technique as with the slider drilling. Put a wooden popsickle stick under the plexi and drill the hole with acrylic drill in the plexi. Then replace the wood by eventual washers and drill with the regular twisted drill through the roll bar.

Continuing on the windscreen. Next task is to align the height of the slider canopy frame with the windscreen.
For this, you can grind some steel from the bottom of the legs of the front bow or add some washers. In my case I had to file a bit more to get it to the final position.

Once that position is locked in, it's time to drill the slider rollers to the slider frame. Don't do this any earlier because once the hole is drilled, the height is defined.
I marked the position for the bolt screw hole on the slider frame and started measuring for the final position of the roller.
This is a critical job, if the roller is not straight, opening and closing the slider will be very difficult.

This means that the direction of the roller must be absolutly parallel to the slider track.
To check this, I held a steel ruler against the roller and verified that the ruler was parallel to the slider track along the entire length.

Did this back and forward facing like in the image below.

Once that's done, drill a pilot hole and finally drill to final size.

Here's the screw installed with some washers (not to engage on the nylon of the nut) I still have to remove this for painting.

Did the same on both side and works like a charm.

Continued drilling the windscreen to the rollbar.
In the image below, note the numbers that indicate the amount of nylon washers to go betwee the windscreen and the rollbar.

Nice alignment all the way down.

I still haven't finalized the cutting of te bottom line on the sides.

Note: do this before drilling as I did. I ended up having to redrill the 2 bottom holes in the rollbar because the windscreen tends to move back bit when fine tuning the sides. No big deal, but better do it first.

Trimming of the sides after marking the location in a straight line following the fuselage top skin.