Using a woodburner set purchased from Walmart. My burner set came with several different tips, one of which is like a #11 blade. Using this blade tip I was able to make a very clean undistored canopy cutout in 5 mins. I used 1/4" masking tape to identify my cut edge and then in my case just ran the hot blade along and around the edge of my canopy frame. The tip of the blade is just hot enough to melt through the canopy and the further the blade is inserted the hotter it gets speeding the cut as desired. Do a few test cuts first to get the hang of it. This cut is 95% complete with exception of some final sanding, and it really only took 5 mins.

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Thanks for the tip, you unknowingly gave my a great idea. I have a Weller soldering iron in which I broke the tip off half way down where the threads are, there is absolutely no way that I can remove the old tip. Whether it be via an easy out or other means, its just in too far to access. However, your wood burner tools gave me an idea to make one out of my old iron! Thanks for turning on the light bulb in my head. Thanks and be well.

Good idea-have not used mine for a canopy, but I do occasionally burn some holes in difficult places, like for push rod relocation, where you can't get a drill to. Comes in handy from time to time.

I have never seen an iron come with a tip like that. I'll have to check into it. Thanks!

I occaisionally attach a #11 blade to my solder iron by wrapping fine copper around. Works well to "cut" away glue joints.

I bought a wood burner kit to modify for burning rivets. It came with one of these blades and I have found several uses for it. I will have to give it a try on a canopy. Thanks!

Also works good for cutting thin fiberglass parts.

Hobbico used to make a #11 blade soldering tip. Maybe they still do?

Yep, they still have it:

http://www.hobbico.com/tools/hcar0770.html

I have one and use it all the time - especially when cutting covering - really you melt it! -