I’m sure there are probably better ways to build them but this is how I did mine. I have almost 200 flight hours on it now and so far everything has held up very well. No cracks or failures. The double gull wing doors are much nicer than the single piper door. Much easier to get in and also much better to load the back seat.
Here are some photos I found on my computer from the build. Note this is when I still had a Subaru engine mounted to it. I changed my mind shortly after these photos were taken. Ill get more photos in a day or two.
Also when I built my canopy I sloped it back so the rear door edge opening is sloped back slightly. That made the windshields fit better and also made the canopy slightly more streamlined by laying the windshields back some. Also I changed the shape of the rear windows. They resemble the Cirrus windows. My door hinges are internal so they don’t show from the outside. I bet my doors are heavier than the factory ones but I have never compared. My dash top is aluminum.032. It goes from the dash to the firewall.
As far as dimensions I just started building and just guesstimated based on how much room the seat would take above the main spar and simulating that while sitting there and measuring head room. I measured a couple piper Cherokees to get in the ball park. The plexiglass windshields are from piper Cherokee windshields that I trimmed to fit. The side windows are Lexan that I purchased from a RV company that builds sky lights for motor homes and trailers. I got the most shallow dome bigger than the door window opening and just trimmed it the size I needed. The rear windows are just flat tinted plexi that I riveted in place.
I built the main structure with Aluminum channel and brackets made from 4130 so it would all bolt together. I then made the doors from marine grade plywood covered with a fiberglass skin. Next time im out to the hangar I will take some photos and send them to you. Thanks for the compliments.
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