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Apr 08, 2020, 12:57 PM
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Making a canopy sill

The easiest way is to use 1/32Ē plywood cut out 1/4 inch larger than the oval shape that you want for the canopy. Soak it in water for 20 minutes then wrap it over the area where the canopy is to be cut out. Keep it in a low humidity area overnight. Unwrap the ply and cut it out with scissors. Cut out the canopy with a thin Dremel wheel or with a thinner diamond wheel from Harbor Freight. The plywood sill now gets epoxied to the canopy opening. Clamp with hobby clamps ( clothspins can work)

Instead of plywood fiberglass use 60 min-24 hour epoxy and fiberglass cloth. This is stronger and insures a better shape. Purchase a roll of clear Monocote or use scrap backing from a colored roll of Monocote. This material does not stick to CA or epoxy and its free usually. Cover the area of the canopy with this material and tape it in place. Lay the cloth 1 -3 once/sq yard over the clear plastic. Carefully brush the epoxy on to the cloth and roll toilet paper over the cloth to remove as much of the epoxy as possible. Donít scrape the epoxy away as it will disturb the weave of the cloth. You can add another layer of cloth and repeat the process. When epoxy fully cures and is hard you will not have to sand the epoxy. Cut out the sill to support the canopy and epoxy in place.
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