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Cozy Construction Chapters.

 

Chapter 4 - Welcome to Building bulkheads

Started 5/18/2003 finished 10/5/2003 Hours to complete:66.5

I took my time so that I could learn, I had never worked with fiber glass and epoxy before. At this time I feel more confident about working with these materials, and I am having fun too. When I first got the foam out to work with it I couldn't believe that it would be strong enough to do the job, will I was wrong it's amassing!

Seat back drawing  Foam after 5min glue up  Seat back foam, first peace of aircraft.

The large workbench sure make it nice, I would of never thought of build one of this size.Glass one sideWeight down to keep flat.

I am going to wait until I get to the point (Chap. 6) of installing the map pockets to get the size just right. I have noticed on other builders web site that they had some mismatch size problems.

Clark foam layout.

Jig saw could not handle the sheet size so I made this jig, works great. I thought it would be easer to move the foam not the saw.

Cutting foam with razor tooth blade gives a smooth cut.

Close up of blade

If you look close you might notice that F28 is to short, it was but with glass and foam you can always fix it.

Forward bulkheads F28

F22

 Doubler's weighted down.   

Instrument Panel:

Cutting parts

Hinge method used to assemble the IP parts    Added stiffener ribs.

After I glassed the stiffener ribs I found a problem, the glass has been pushed away from the foam, so I sanded it and put on a replacement peace of glass.

Landing gear bulk head, the large green part are the solid glass attachment points.

The two peel & ply strips are where the reinforcement lay-up edges are. This made for a smooth transition.

Final lay-up of landing gear bulk head.

Firewall: print tracing

Tracing on to plywood

Cutting the plywood parts Firewall topTop of Firewall

Glassing the top

Glassing the two center part after the blind screws are installed.

Bottom with engine mounts hard points and the blind screws.

On to Chapter 5

 

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This site was last updated 05/22/14