DIY Edge Tool for Canopy Skirts

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edge-bending-tool
The creasing tool has a slot as deep as the desired kink. The shallower slot is the one we used—it helped to use a little silicone grease to lubricate the slot.

While shaping the aluminum canopy skirts for our F1 project, we needed to put a relatively sharp crease into the top edge—about 3/4 inch down. Since this was beyond the reach of a typical edge-breaking tool, we found a block of Delrin we had lying around and used the bandsaw to cut a notch—coincidentally the same width as the skirt material thickness—3/4 inch deep.

edge tool IMG 6546
Expect to wear out your wrist doing the work—this was 0.032″ aluminum, and it takes a little force to get it to bend.

We held the skirt in our vise and ran our homemade “creasing tool” down the length, introducing a twist with the wrist. It takes some force, and you need to keep repositioning the material in the vise, as you can really only kink it where it’s firmly held.

The result is a nice, even crease at the desired distance from the edge—just one more metalworking arrow in your quiver.

IMG 6545 scaled
Let the kink develop over several passes—don’t try to reach the final angle all at once.
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Paul Dye
Paul Dye, KITPLANES® Editor at Large, retired as a Lead Flight Director for NASA’s Human Space Flight program, with 50 years of aerospace experience on everything from Cubs to the Space Shuttle. An avid homebuilder, he began flying and working on airplanes as a teen and has experience with a wide range of construction techniques and materials. He flies an RV-8 and SubSonex jet that he built, an RV-3 that he built with his pilot wife, as well as a Dream Tundra and an electric Xenos motorglider they completed. Currently, they are building an F1 Rocket. A commercially licensed pilot, he has logged over 6000 hours in many different types of aircraft and is an A&P, FAA DAR, EAA Tech Counselor and Flight Advisor; he was formerly a member of the Homebuilder’s Council. He consults and collaborates in aerospace operations and flight-testing projects across the country.

1 COMMENT

  1. Ha, great minds think alike. I came up with the same idea a few years ago.
    Mine is smaller and only 3/8″ deep, for the typical skin break.
    A little bit easier to control for me.
    Didnt think of grease in the slot.
    Thanks for the tips.

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