Removed the peel ply and finished trimming the aft
face of the IP. Sanded all edges smooth. I was concerned by some
dry spots and bubbles under the UNI layer. I finally contacted an
EAA technical counselor. Marvin Wahl of Denver came by to have a
look. He felt there wasn't a problem. I'm still concerned a bit but
the IP isn't load bearing.
Prepared and glassed the front face of the IP. Applied slurry,
two layers of BID and one layer of UNI (again, above the leg
holes). Covered face with peel ply. Knife trimmed the holes and top
edge after a bit of drying.
Cut out the foam for the three pieces making up the landing gear
bulkheads. Used print outs from a CAD file obtained from Zeitlin's
||Removed the peel ply from the IP and trimmed and
sanded all the edges and cutouts. Next I cut all the stiffeners
that go on the front face of the IP. I used 5-minute epoxy to
attach the two horizontal stiffeners in place. I then applied the
one layer of BID to the upper surface of each stiffener.
Next I intended to make the landing gear bulkhead hardpoints. I
cut all 22 pieces of BID at 8" x 12". I layed down a 8 x 12 pattern
then placed a sheet of saran wrap over it. Next I layed down a
sheet of peel ply. I then began laying out the layers of BID. As I
worked I started to notice that the layers were shifting around.
After seven layers I realized I had a big problem. Due to the
shifting the seven layers didn't all completely cover the 8 x 12
area. I made the BIG mistake of not taping the saran wrap down. So
even though I made sure each new layer covered the 8 x 12 area, the
area was is a slightly different spot each time - oops. I attempted
to salvage the situation by removing each layer and setting them
aside. I then taped a new sheet of saran wrap down and attempted to
relay the fiberglass. No way, no how. Isn't going to happen. The
epoxy was getting thicker and I couldn't even get the first layer
shaped right. #?!?$%?@$! I ended up scrapping the mess. It was too
late to start over so I will tackle this again another night
starting with cutting seven new rectangles.
||Trimmed and sanded smooth the layup on the
stiffeners. I then applied to double layer of BID on the bottom
surface of the stiffener and formed the lip.
Completed the 22 layer layup for the hardpoints. This took hours
to do. I didn't finish until 2 in the morning! Both sides have peel
ply and the whole thing was covered with saran wrap and weighted
||Removed the peel ply from the hardpoint payup and
cut it square. Discovered it is 5/16" thick instead of 1/4". Posted
message to mail list and got about half saying OK to use and half
say to do it over.
||Trimmed the second layup on the horizontal IP
stiffeners. Attached the foam for the two vertical stiffeners with
5-minute epoxy. Did the first layup on these stiffeners.
||Trimmed and sanded the previous layup. Prepared
and performed the second layup on the stiffeners.
Cut all the glass to redo the landing gear bulkhead
||Trimmed and sanded the final layup for the IP
Redid the 22 layer layup for the hard points. I seemed to do a
much better job this time. I made use of a hair dryer more. This
seemed to help when ever the epoxy started to thicken a bit. I
definitely used less epoxy than last time. I'll know for sure
tomorrow how it turned out.
Cut out the four 1"x1" aluminum engine mount inserts for the
firewall. Cut the four corresponding holes in the plywood for the
||Removed the peel ply from the hardpoint layup.
Overall it was much better. The thickness was 0.28" instead of
0.32". I rubber cemented the patterns to the layup and cut out the
four hardpoints. I then cut the landing gear bulkhead foam to take
Cleaned up the shop a bit.
||Epoxied the hardpoints in place with the bulkhead
foam. Sanded everything smooth. Sanded the bevels on the upper
front landing gear bulkhead.
Sanded both sides of the firewall pieces in preparation for
||Did the layup on the forward face of the two
forward landing gear bulkhead pieces. Each had 2 layers of BID and
one layer of UNI. I know I am going to have issues with the peel
ply as usual. I tried one builder's idea of putting plastic over
the peel ply before squeegeeing it. It seemed worse. Eventually I
will get it figured out.
||Removed the peel ply from the previous layup and
trimmed the glass to the foam edges. The masonite used to weight
the lower bulkhead was stuck to the peel ply. It took an hour to
get it removed. I used a chisel to thin the masonite enough to
remove the peel ply!
||Did the layup on the aft face of the forward
landing gear bulkhead. Two layers of BID and one of UNI. Added peel
||Removed peel ply and trimmed all glass edges. Had
some trouble with the tape. I should've removed it while the glass
was still wet.
||Attended my first EAA Local Chapter meeting. This
was chapter 301 held at Centennial airport. I had another technical
counselor take a look at a bulkhead. He was pleased with it. This
made me happy since I was worried about the dry spots I was getting
from the peel ply.
||Did layup on front face of the aft landing gear
bulkhead. Two plies BID and two plies UNI over whole face then 8
layers UNI over each ear.
Glued in aluminum attach points in real firewall. Did single ply
BID layup on the aft face of all the firewall pieces.
||Removed all the peel ply from the landing gear
bulkhead and all the firewall pieces. Trimmed and sanded flush the
Marked and drilled the 3/16" holes for the blind screws in the
||Countersunk all the holes for the blind screws in
the firewall. Ground flats on all the screw heads and roughed up
the screws so the epoxy has something to stick to. Floxed all the
screws into place.
Did the final layup on the aft landing gear bulkhead. This
included two plies BID and two plied UNI overall plus three plies
UNI on the ears. Peel plies the whole face.
Glassed the aft face of the firewall with one ply BID. Peel
plied the whole face.
||Removed the peel ply from the landing gear
bulkhead and trimmed and sanded the edges smooth.
Removed the peel ply from the firewall pieces and trimmed and
sanded all the edges smooth.
Cleaned up the shop in preparation for chapter 5.
||Layed out and nailed down jigs FJA, FJB, and FJC
for making the longerons. Prepared and epoxied the 6 105" strips to
make the longerons. Secured them in place against the jigs.