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||Created template for NACA scoop, outlined on fuselage bottom, cut out
foam, trimmed to shape, and micro'd foam to fuselage bottom. Cut out the wooden
braces for the LG bulkheads and floxed in place. Cut out the foam to go on the
outside of these braces, but did not micro in place, as the braces' flox was still drying.
||Micro'd the foam to the braces. Cut out the braces that go between
the FW and aft LG bulkhead. Floxed in place, added 2 plies BID, and micro'd 2"
foam over them. Now, in order to finish the scoop you're supposed to use 3/8"
PVC foam in the space between the FW and aft LG bulkhead, but I am out of this kind of
foam. First I didn't have enough foam for the spacers, then I didn't have enough BID
for the taping, and now I don't have enough foam for the scoop. In all fairness, I
believe that this last shortage is my fault, for not saving the scraps from the fuselage
bottom. But to be short for three separate things in the space of a couple of days,
well, grrr. I've got two separate orders in at Wicks to send me more stuff, and now
I'm just fiddling around until it arrives.
I also prepared the 22" sanding block
today, in preparation for sanding down the NACA scoop.
There are a bewildering number of details that the plans are silent about, or that you
have to be Sherlock Holmes to figure out. For example, the horizontal braces between
the FW and aft LG bulkhead. The dimensions in the plans suggest that one side is
essentially square, and the other is angled to fit up against the side braces (where the
bevel is). But, the square side cannot actually be square, it has to be angled to
fit the line of the NACA scoop. If you cut the things to the dimensions in the
plans, they won't be long enough. So the plans say to trial cut from foam first, but
they don't explain why. Elementary, my dear Watson. Okay, then, you put the
2" foam on top of them, but the plans don't say anything about shaping this foam down
to the contour of the bulkheads. You have to notice in the pictures at the end of
the chapter, where there's a reference to this. So many of the little mistakes I
make that I have to go back and correct could have been prevented by a little more clarity
in the plans. I'm being as careful as I can be, but often I don't realize I've made
a mistake until I'm past it. Sometimes it seems to me like the plans are written for
someone who already knows how to build one of these things, and the plans are there just
to remind you of the major steps, without worrying about all the little details.
||Cut out and installed 3/8" PVC for the rear part of the
||Sanded down 1/2 of the scoop, cut out the ridge for the
||Sanded down the other 1/2 of the scoop, cut out the
aluminum inserts and floxed them in place. The cost was for a band
saw, which turns out to be an essential piece of equipment; and a
||Shaped the tapers on the sides by the FW. Started
the 45-deg cut along the bottom of the fuselage sides. I made a
12" long blade for my jig saw from a band saw blade to make the cut.
||Finished the 45-deg cuts, did the hand cuts, and sanded
and shaped the fuselage sides, on the bottom.
||Brake & F22
||Today I sanded the 1/16" depression around the landing
brake and F22. The popsicle sticks used for stirring epoxy are
perfect for this. Also marked and cut out the step reinforcement.
||Cut the step reinforcement to fit, and micro'd it into
||Sanded down the step reinforcement to align with the
fuselage exterior. Ordered the antenna kit from RST, so it may be
a couple of weeks before I can glass the bottom.
||Put the 1" border of duct tape around the landing brake.
||Cut out the BID and peel ply for the 2 plies inside the
scoop. Will probably glass this tomorrow.
||Glassed the scoop, 2 plies BID, peel ply.
||Decided to go with the marker beacon antenna on the
bottom, as suggested by RST. Cut a trench for the coax and a hole
to enter the cabin fore of the IP, cut the foil tape and installed it in
place, and soldered the coax to the tape with the toroids in place.
That should be the last thing to do before beginning to glass the
bottom. Now all I need is a nice, warm day...
||Made a flox corner at the scoop, micro'd the entire
bottom, and then laid the glass (with my wonderful wife's help!).
2 plies UNI at 30-deg, plus 1" overhang at F22 and the bulkheads/FW.
Added the reinforcing UNI layups on the gear attach and engine mount
points. Added peel ply. Boy, it doesn't sound like a whole
lot, but it took all day!
||Shaping the sides
||Cut the templates for shaping the sides,
began the shaping.
||Shaping the sides
||Completing the shaping of the sides.
||Glassed the pilot's side of the fuselage. 3 plies
UNI, 3 reinforcing layups on the top, 3 plies reinforcing UNI at the
engine mounts, 2 plies BID at the same place, and then peel ply. I
also trimmed the glass that overlapped the bottom, and peel-ply'd the
seem. Dude, this was a LONG day. I'm running low on all
supplies (UNI, hardener, resin, peel ply), so I might have to wait until
I order the next chapter's supplies before finishing the other side.
||Cut the glass for the other side; we had enough!.
Poured one cup of epoxy to start the glassing, and then convinced myself
that I don't have enough epoxy, so I've decided to wait until the next
order comes in.
||Order came in yesterday. Glassed passenger side.
This went much faster than the pilot side! Got a drop of epoxy in
my left eye, yikes! I ran to the nearest bathroom and washed out
my eye, and then ran upstairs where Amy rinsed my eye with saline, and
then with more water. We then waited a few minutes to see how my
eye was doing. I thought it was swollen, but it didn't look like
it to her. After about 10 minutes there was no sign of any lasting
harm, and no loss of visual acuity, so I went back to work. Now at
the end of the day I'm glad to report that there are no lasting effects.
It was just the tiniest of specks that went in my eye, but I could feel
it and instantly knew I was buggered. I went to Lowe's afterwards
and bought myself some splash-guard goggles.
||Trimmed the glass cloth, sanded the edges, and took the
fuselage down from the A-frames and let it rest on rubber mats on the
floor. We took the requisite right-of-passage photos with us
sitting in the plane. :)
Chapter total: Time 68, Cost $91.00
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