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Cozy Mark IV : Time and Expenses
Chapter 8: Headrest, Heat Duct, Seat Belts & Step
In this chapter you will construct the shoulder support, headrests, and
aft heat duct, installing hard points for installation of seat belts and
shoulder straps.
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Chapter 8
# |
Item |
Date |
Cost |
Time (hrs) |
Comment |
1. |
|
|
$681.38 |
|
Chapter 8 materials order from Aircraft Spruce. |
2. |
Headrests and support |
2/12/05 |
|
2 |
Traced out the headrests on
the PVC, micro'd and glassed. Cut out the support and made a
trial-fit. I can't check it against the fuselage yet, because it's
still drying, so we'll pick this up again tomorrow. Cut out the
birch plywood inserts. |
3. |
Headrests & support |
2/13/05 |
|
3.5 |
Cut out and 5ME'd together the
headrest pieces. Trial-fit the shoulder support in the fuselage,
did a little trimming, and then 5ME'd those two pieces together.
Installed the birch plywood inserts. |
4. |
Shoulder support |
2/19/05 |
|
4 |
Cut out cloth for the shoulder
support. (BID, 2 plies outside, 1 ply inside, and 3 5"x5" squares
to cover the inserts.) Fashioned 3 jigs from foam for the
support, micro'd the inside, and laid the 1 ply BID inside. Left
it to dry. While it was drying, I made the nutplates to go under
the inserts. Cut some 1/16" aluminum to 1-1/4" x 1-3/4" (4
pieces), aligned it over the inserts to mark the center, and cut a 1/4"
hole through each one. With the 1/4" bolt attached to the anchor
nut through the hold, I drilled 3/32" holes for the rivets, and then
attached the rivets. After a short break, it looked like the
inside glass on the support was dry enough, so I installed it on the
seatback, wet out and peel ply'd the overlap. |
5. |
Shoulder support |
2/20/05 |
|
4 |
Trimmed the overlap from
yesterday. Wet out and cut the 12-ply 1-1/4" squares of BID,
installed over the birch plywood inserts. Micro'd the shoulder
support, and applied the 2-ply BID overall. Cut out the pieces for
the heat duct and glassed the insides. |
6. |
Heat duct |
2/21/05 |
|
4 |
Assembled the heat duct with
5ME (+ flox), added the 7 plies of UNI reinforcement, and put a 2-ply
BID overall. Let dry, trimmed. Started glassing the
headrests (not yet attached), 2 plies BID. The cloth is all cut,
but I only got around to 2 plies on one side today. I need to
replace the brushes on my Dremel, it started to lose power tonight. |
7. |
Heat duct, headrests |
2/24/05 |
|
1 |
Trimmed the glass on the
headrests, and added 2-ply BID to the other side of one of them.
Cut the hole on the rear duct, and floxed the transition piece in place.
The problem with my Dremel wasn't the brushes; I replaced them and it
still doesn't work. So I came home from work tonight with a new
Dremel. I wonder if some epoxy somehow got up inside there and
gummed it up. Oh well. On the good news side, the main
landing gear strut arrived yesterday from Feather Lite! Yeah! |
8. |
Heat duct, headrests |
2/25/05 |
|
1 |
Floxed and taped the duct in
place, finished the glassing of the headrests. |
9. |
Headrests |
3/20/05 |
|
.25 |
Trimmed the glass around the
head rests. This chapter is now complete, except for some small
things that get put off until later, such as the step and the seat
belts. |
10. |
Reinforcing layups |
7/3/05 |
|
3 |
Cut out BID/UNI (4/3 x 2) for
the reinforcing layups over the front & rear ducts, wet them out and
installed them. NOW this chapter is complete (except the step &
seat belts). |
Chapter total: Time 22.75, Cost $681.38
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