
Sonex builder Steve Pettyjohn had the unfortunately typical experience of cracks propagating from the lower siderail holes on his canopy.
When installing per plans, you must force the bubble of the canopy sides to conform to the straight fuselage sides. This puts a lot of stress on the canopy's right and left bottom edge. Despite heeding all the precautions outlined in the Sonex instructions, I cracked the canopy in two places on the right side, and one long crack on the left when drilling the holes along the bottom edges. After much swearing, I decide to try out Chris' joggle strip idea and try to salvage my canopy rather buying a new canopy and starting out over again. Purchasing a new canopy would not guarantee that the very same results would not happen again.I do believe this may be a superior method. The more holes drilled in the acrylic - the more likely a crack will develop. Also, the metal side plates easily make the transition from the curved bubble canopy to the straight fuselage sides much better .The drawbacks to this method are the aesthetics of the longer metal side plates and the staggered look when viewing the aircraft from the side, and the slight reduction in downward visibility. I believe any reduction in downward visibility will be insignificant due to pilot's line-of-sight being higher up.








