Cozy Mark-IV Ser. #0991 Work-In-Progress
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CHAPTER 8 - SHOULDER SUPPORT & HEAD RESTS
  Seatbelt Attachments - Birch block set in place and ready for reinforcing layups. This is typical of all the outside floor mounted attachment points.
Shoulder support - still wet - ready to be dropped in place and epoxied in. Note that I have already installed the nut plates. I carefully measured and drilled the holes and filled them with white wax so the holes could be accurately opened after the additional layups. This worked fine with MGS epoxy because it is almost clear when cured.
Seatbelt attachment brackets all ready to be floxed in place (well except for a little hole in the upper ear where the seatbelt attaches).

Part of the building experience is learning how to fix what you have messed up... During the bottom layup process I had an assistant (the first time anyone has help on the project!) who forgot to mix the epoxy after getting 4 squirts from the pump. She discovered the error right after she poured some of it onto the glass. In my nievity I thought we could scoop most of it up and then just mix what was left with good epoxy. WRONG! Days later - by accident - while the fuselage was upside down I had a flood light pointed at the bottom from underneath. When the skin in that area got warm it began to look slick and a drop formed. That meant that the epoxy was not cured in that area - and never would. So I put more heat on it to get the epoxy to liquify and show the extent of the problem.

To the left is a picture of the affected area. The square lines are at least 1 inch from any area that looked suspicious or after probing with razor knife and drill was found to be soft.

The "cancer" has been removed - there are now "clear margins". I have probed around the edges to ensure that the rest is good and hard.
Another angle of the affected area. Note also the 2-3" area around the hold is sanded thoroughly.
Foam is in and Micro'd ready for glassing with glass lapping 3" all around. That should be as good or better than the original floor - albeit a little heavier.

The step that I am using is one that is in use by a number of Long-EZ and Cozy builders. It consists of an aluminum tube nested inside another aluminum tube. The inner tube can be extended outward 6-7" via a nob that extends through a slot in the outer tube (see the slot in the tube). The outer tube is glassed onto the forward face of the Instrument Panel just below the leg hole.

To the left - tube is being floxed in place.

Step tube being floxed in place - then it gets glassed with a couple of layers of BID - except for the slot of course!

Reflections

 

Now on to Chapter 9 - Main Landing Gear and Landing Brake!!

 

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