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Cozy Mark IV : Chapter 14
Center Section Spar
In this chapter you will build the center section box spar which joins the wings to the fuselage.
Pictures and commentary will go here as the work progresses. See also time and expenses related to this chapter.
| Step 1: Centersection jig | Completed 11/11/07 | |
| Step 2: Assembly of foam parts | Completed 11/18/07 | |
| Step 3: Interior Layups | Completed 11/20/07 | |
| Step 4: Install the forward face | Completed 11/20/07 | |
| Step 5: Outside hard points | Completed 11/23/07 | |
| Step 6: Spar cap layup | Completed 12/24/07 | |
| Step 7: Shoulder harness blocks and outside layups | Completed 12/30/07 | |
| Step 8: Hardpoint reinforcement | Completed 1/1/08 | |
| Step 9: Access for wing attach and end layup | Completed 1/19/08 | |
| Step 10: Installing in the fuselage | (pending completion of wings) |
| Step 1: Centersection jig | |
| 11/10/07 Made part D and bondo'd to table. |
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| 11/11/07 Completed construction of the jig. Now just waiting on the chapter kit to arrive. |
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| Step 2: Assembly of foam parts | |
| 11/18/07 Cut out all the foam for the spar. |
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| Step 3: Interior Layups | |
| 11/18/07 Built spar box. |
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| 11/18/07 Long view. |
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| 11/18/07 Cut out all LWA inserts.
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| 11/19/07 Interior layups |
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| 11/20/2007 Cut a 1-1/2" hole through CS6 & CS7, and installed a plastic grommet with 5ME. This is to allow cables from the wings through the box. I wanted to do this now, before the top (CS4) is installed and this becomes inaccessible. |
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| Step 4: Install the forward face | |
| 11/20/2007 CS4 is installed and held tightly in place for cure. |
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| Step 5: Outside hard points | |
| 11/21/07 Cut out templates for spar caps. |
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| 11/22/07 Removed spar from jig, preparing for shear web layup. |
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| 11/23/07 Sanding troughs for spar cap. |
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| 11/23/07 I did this primarily with a hacksaw, and came after with a sanding block to finish. |
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| 11/23/07 Cutting the 1"x1/2" angles. |
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| 11/23/07 Getting ready for the shear web layup. You can see the aluminum inserts in place here as well. |
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| 11/23/07 Probably the longest day yet, but I wanted to get this done! |
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| Step 6: Spar cap layup | |
| 12/8/07 The two spar caps are done. |
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| Step 7: Shoulder harness blocks and outside layups | |
| 12/30/07 Cut out four spruce pieces. |
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| 12/30/07 This is where they'll go... |
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| 12/30/07 ...just like that. |
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| 12/30/07 Everything's ready for the 4-ply UNI layup. |
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| Step 8: Hardpoint reinforcement | |
| 1/1/08 Positioning LWA2 & LWA3 |
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| 1/1/08 Reinforcements are done and curing. |
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| Step 9: Access for wing attach and end layup | |
| Step 10: Installing in the fuselage |