Chapter 4 - Step 2

This covers the building of the F-22 bulkhead and it doubler. This is made from 0.2" ??? foam. F-22 is made from two sheets due to its size.

This also covers the building of the F-28 bulkhead. This is made from the same foam. Covering of both pieces is done at the same time.

F-22 Foam December 10, 1999. Here are the foam pieces making up F-22 and the doubler.

Gluing F-22 December 10, 1999. The two halves of F-22 are being glued together with 5-minute epoxy. All the scraps are holding up the pieces so the epoxy isn't touching the table.

F-28 Foam December 10, 1999. F-28 cut to shape.

Fiberglass cut for F22 & F28 December 18, 1999. All the fiberglass cut for the first layup of F-22 and F-28.

After first layup December 19, 1999. Here are the two bulkheads flipped over after the first layup has cured.

After second layup December 19, 1999. The two bulkheads after applying the second layup. Both are covered with a big sheet of peel ply.

Trimming December 23, 1999. The outer edges of both F-22 and F-28 have been trimmed. The inner cutouts still need to be trimmed. This was quite a pain. I wish I had knife trimmed these earlier.

Close-up December 23, 1999. Here is a close-up the top of F-22 showing the doubler and all the layers of glass.

Finished F-22 December 30, 1999. The completed F-22 showing the front face.

Finished F-22 December 30, 1999. The completed F-22 showing the aft face.

Close-up F-22 December 30, 1999. Here is a close-up the top of F-22 showing the doubler and all the layers of glass.

Close-up F-22 December 30, 1999. Here is a close-up the top of F-22 showing the doubler and all the layers of glass.

Finished F-28 December 30, 1999. The completed F-28 bulkhead.