jpolenek Posted September 29, 2007 Share Posted September 29, 2007 While intending to stick with the plans as much as possible, one modification that I do want to make is to re-shape the canopy for more side-to-side headroom. (Cozy MKIV). There are limitations to what shapes can be achieved by free-blowing, so drape moulding may be the way to go. (i.e. moulding the plastic directly over a male plug.) I tried to email Todd Silver of Todds Canopies numerous times but never got a reply. However, based on his website, drape moulding may not be one of his capabilities anyway. I called Airplane Plastics, the "approved" canopy supplier for Cozys. Jeff Rogers was extremely helpful and took his time to explain his processes. Unfortunately, he doesn't do drape moulding either. His way of getting custom shapes is to use the plug to build a 1/4" thick fiberglass female mould, build a steel frame around it, and vacuum-form the plastic into that. This process is somewhat more complex and is really intended for mass production, so it is cost prohibitive for a one-off for the average person. There must be a poor man's way of drape moulding a canopy and achieving decent optics if enough time and care is taken. I'd like to build the plug to the right shape and then either give it to a shop that will mould it for me (at a reasonable price), or use some home-made techniques to do it. Can somebody direct me to a resource for learning how to do this? - someone who has done this themselves with good results? - a mould shop that has this capability? - an EAA advisor who can point me in the right direction (I am a member.) - books, websites, etc. Joe Polenek Quote Joe Cozy Mk IV #1550 Link to comment Share on other sites More sharing options...
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