I
cut up the foam pieces per plan (page 14-7). They were pretty straight forward
as the fixture boards. When it was time to carve out the local depression, I was
a bit confused on which side is up, but I found my answer on the second
paragraph of page 1, "Note that the top of the spar is flat" -
that means Part D is the on top.
Per
page 1, figure 2, the plan shows 'sand CS2 or CS3 flush with the jig', I went
ahead and sand CS2 AND CS3 flush with the jig. To achieve this, I stood CS2 and
CS3 tightly together, then I clamp a straight board
with its edge parallel to the top of part D and sanded both CS2 and CS3
at the same time - giving me a perfect leveled top edge.
It
is obvious that CS3 should be 90 degrees to CS1 and parallel to CS2. I cut up a
bunch of 2" x 13" boards to be used as small fences to keep CS3 in
place. Using a couple of angles, I position the fence boards and used a hot glue
gun to hold them in place. It worked quite well.
If you look close, you can see the packing tape I place on the fixture to keep the foam from sticking onto the fixture during cure.
Then
I microed the foam boards in place. Weights were used to hold them down during
cure. Note that I also used duct tape to hold both CS2 & CS3 against its
fences.