Made a foam blank for the canopy linear actuator lower mount.

Carved, filed and sanded the window edges to shape and smooth

Measured, marked then cut the holes in the turtleback for the windows.

Marked the holes for the windows in the turtleback.

Microed the turtleback then did the 2 ply UNI layup on the outside. Peel plied the layup then cleaned up.

Made the aluminum insert for the turtleback. Cut glass, filled the epoxy pump and laid plastic for the next layup.

Sanded the depressions into the foam on the turtleback as prep for the outside layup

Made a yardstick-based sanding board and sanded the outside of the turtleback smooth.

Marked window locations on the foam in pencil.

Made and installed a plywood brace for the aft end of the TB then hot glued it in. Trimmed the ends of the drip rail foam and layup with the Fein. Removed the screws holiding the TB foam to the jig, then removed the TB from the jig. Cleaned up and test fitted the TB onto the fuselage.

Wet out the 2 x BID 1x UNI layup for the drip rail. Microed the foam, applied the layup, stippled & applied peel ply.

Finished sewing the drip rail foam into the turtleback, cut fiberglass for the next layup, filled the epoxy pump and cleaned up.

Sewed one half of the drip rail aft piece into the turtleback.

Tried stitching into the TB the drip rail foam; too stiff when glued all up together.

5 minute epoxied together two beveled foam pieces. 36 grit sanded the inside there the drip rail installs and taped forward of the cut line.

Cut beveled foam pieces for the drip rail.

Laid out the drip rail cut line. Drilled the holes to make same from the outside then made up some 3/8" foam pieces for next steps.

Cut glass. Laid up enough 2 ply BID 2" tape for the front of the TB1. Made a flox corner then applied the tapes, cleaned up.

Floxed in TB1 on one side. Made 2 ply BID tapes and installed onto the same side of TB1.

Fixed the lower 'holes' in TB1 to match, hot melt glued spacers into the turtleback for the TB1 install / layup

Re-installed the side hinges. Stood the turtleback up, made some 3 3/4" blocks and test fitted TB1 in its place.

Finished trimming, filing and sanding TB1. Cut out the blank piece for the acuator mount and fitted it into TB1.

Cut the outside edges of the TB1 to rough shape, sanded and fit until it fit closely inside the turtleback. Re-trimmed the shell pieces to be 2" wide.

Sawed, sanded and filed the edges and inner holes of TB1

Trimmed the TB-1 edges and the blank for the actuator mount. Using the Fein and saber saw, rough cut out the holes in TB-1.

Finished cutting glass then did the 3 ply BID, 1 ply UNI layup on both sides of TB1. Made a small piece for the actuator with the same layup schedule with a 3/8" aluminum tube buried in it. Added peel ply, vacuum bagged both parts, weighted them and cleaned up.

Laid out my design for TB1 using the paper print out. Cut a piece of 3/8" OD aluminum tubing for the actuator mount, filled it with wax and 5 minute epoxied into a slot in the 3/8" PVC. Laid out parts and cut all the UNI pieces I would need.

Cleaned up; test fitted the turtleback (in the jig) onto the fuselage.

Trimmed the ends of the turtleback with the Fein

Did the 2 ply UNI layup on the inside of the turtleback. Measured and marked, cut glass, added the tape to the joints, micro, squeegee, trim, peel ply, the whole enchilada.

Epoxy / floxed on the 3" flange, pinned it down then peel plied the joint

Finished installing foam pieces into the turtleback jig. Trimmed the top edge flush for the 3" flange. Cleaned up.

Continued cutting and fitting foam pieces into the turtleback jig

Vacuumed up all the foam mess from the previous days' work.

Leveled the top of the frame, left side, then taped the whole jig with box sealing tape. Cut some foam to 6" strips and started fitting / screwing them to the jig.

Glued some foam blanks together with foam in a can

Finished installing the lath pieces, ground off some screws & micro drops then vacuumed the whole jig / cleaned up

Continued assembling the turtleback jig; added the lath strips and frame pieces

Marked the jig square then started assembling w/screws and washers.

Dry assembled the turtleback jig that I borrowed from Ron Treml; originally built by Bob Forster

Measured and test fit the canopy. Recognized I'd need to re-draw jigs 1-5 for the Texas Cozy canopy.

Drilled holes and tested bolt installs for canopy hinges

Cleaned up same and tested - they work great!

Floxed on hinges

Cut hinges for the canopy hinge and made jigs to install it