Fitting the WD-643-SS canopy brace - 2.5 hours

 Drilling the top most bolt of the canopy brace is going to be fun. How to drill a hole through the center point of a round tube on a receiver in the roll bar that is only half round. Honestly I don't know how I would have done this without a 3D printer.

 I designed a cap that installs over the roll bar receiver and with #40 pilot holes for the mounting bolt. Working in CAD I can align the proposed mounting holes perfectly in a round tube and then just have to project those out to suite the half round receiver. 

 

I checked the positioning of the pen marks and confirmed everything was square. Now...How to drill the hole. There is no doubt that if I drill these by hand the hole will be terrible, but there is no way I can drill them in a drill press. So the 3D printer to the rescue, I can just add on a drill guide to my cap design.

The drill guide makes a prefect and perfectly aligned pilot hole. 

Using the 3D printer again, I made a small saddle that allows me to get a nice tight fit of the brace into the receiver. 

 

Once the brace is drilled to #40 using the pilot holes in the receiver. It is extremely quick and easy (and accurate) to up-size the hole to #30, #19, 3/16" and finally 1/4" for the AN4 bolt.