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Just completed installation of this dust cover today and the process was slow
going at times. Also, more than the usual amount of colorful language was
required. For those of you who have not yet started this project, these few
tips will significantly lighten your workload. The forward edge of this cover
needs to rest on tabs that are bonded to the rear of the header tank.
Fabricate these tabs and attach them with the header tank on your work bench,
not on the plane. You'll need to remove gelcoat from the header tank when
bonding it to the forward deck and when attaching canopy hinges so at this
time, go ahead and remove 2 1/2 to 3 inches of gelcoat along the entire top
rear exterior wall of the tank. I had to remove this gelcoat and attach the
tabs with the forward deck and canopy in place so this proceedure required
several extra cans of beer. I located the tops of my tabs 3/8" below the top
of the deck. Also, before starting to fit the dust cover, cut it in half down
the middle and fit each piece separately. You will need to have the plexiglass
installed in the canopy frame and the final fit of this frame to the fuselage
so that you can precisely locate the cover relative to the plexiglass. I
temporarily located 1/4" shims along the forward plexiglass/frame bond line so
I have this minimum clearance between the cover and canopy. Don't rush this
part of the project, take the time to do it right because you'll spend a lot
of time eyeballing it during 2000 hours of flight!

Angier Ames
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