Log Entries - Chapter 4

Wed 10/27/99 4 Read chapter 4 in great detail and compiled a list of questions. 2
Sun 11/14/99 4 Began chapter four. I glued two sheets of H45 PVC together for the front seatback and cut to size. Beveled one edge to 45 degrees. I messed this up a little. Got it fixed but the seatback was now a little short. I edge glued a little more foam to the end and retrimmed to length. This took way too long to do. 2
Mon 11/15/99 4 Traced and cut four permanent firewall pieces from birch plywood. Had quite the puzzle trying to rough cut the four pieces on my bandsaw. I still need to sand the edges to the lines. I used a combination of the CAD drawings and some freehand tracing to make the templates. I then rough cut the templates and used rubber cement to attach them to the plywood. 4
Thu 11/18/99 4 Cut out temporary firewall. This was done very roughly. As best as I can tell the only important features are the centerline, the six spar cutouts, and a reference waterline. I sanded the bevel cut I made on the front seat back. I'm still waiting for my epoxy pump. My garage only heated up to 68 degress tonight with an outside temperature of 33. I guess I need more heat. 2
Thu 12/9/99 4 Using the cad file I created print outs of F-22, F-28, IP, and landing gear bulkheads. 2
Fri 12/10/99 4 Cut out the F-22 bulkhead and the doubler from the 0.2" foam. I used an X-acto knife and are my hands sore. That thin little foam is tough. I'm not looking forward to cutting F-28 and the IP. I'll probably use the band saw on the next pieces. I managed to make F-22 from only two pieces. This made gluing them together with 5-minute epoxy fairly easy. I documented the epoxy pump hot box I also added some pictures to the chapter 4 page. 3
Sat 12/11/99 4 I did the first layup on the front seatback - two plies of UNI on the front. It took me a long time to do this. I hope things get better. I put slurry over the whole face, added two plies of UNI, and covered with a big sheet of peel ply. I knife trimmed three of the four edges after the epoxy setup a bit. I didn't want to cut the fourth because I wasn't sure if I would get the peel ply off. This piece is so much bigger than the practice parts. I really felt like I didn't have a clue. I'm sure things get better but I really need a sanity check by having someone else look this over. 3
Sun 12/12/99 4 I cut and sanded to shape the F-28 bulkhead. It was much easier using the band saw and a sanding block. Removed the peel ply from the seatback. Nice finish. There are a few spots that may be a bit lean. I need to get someone to look at them. I then cut the fourth edge flush using the band saw. I them sanded smooth all four edges. I then beveled the bottom edge, rounded the sides, and cut all the corners to be floxed. I did the second layup - one ply of BID. First I floxed all four edges. Next I slurried the face. I then added the ply of BID. This took two pieces to cover the whole seatback. I then peel plied the whole face. I had a problem while doing the peel ply. While squeegeeing the excess epoxy I formed a bulge where the two pieces of BID met. I had to lift up half the peel ply, smooth the joint, and layup the peel ply again. No fun but all went well after getting some bubbles out. Flox corners are tough. It's hard to get the flox to be flush. After applying the glass it appears the flox has shrunk some or oozed elsewhere. 6
Sat 12/18/99 4 After a week off of working and Christmas shopping I was ready to work on the plane again. I started off by finishing the seatback. I removed the peel ply, trimmed all the edges with the band saw and sanded the edges smooth. Overall not too bad. The two corners were the rounded edge and the beveled edge meet are the worse parts. These will need some repair. Next I glassed the aft faces of F-22 and F-28. No real problems here. I did the two plies of BID on F-22, added the doubler, added the two plies of BID and one ply of UNI, and then peel plies the whole thing. I do have two issues. The peel ply does not cover the "ears" of F-22 or the edges of F-22 next to the doubler. The other is going to be trimming the glass on the side of the doubler. 5
Sun 12/19/99 4 Cut all the glass for the forward faces of F-22 and F-28. 24 pieces in all. Applied slurry to the faces and the added the 2 BID and 1 UNI layers to F-28. Next I added the 2 BID layers overall to F-22, added the 1 UNI layer above the leg cutouts. Finally I added the alternating layers of BID and UNI down the sides of F-22. This was all covered with a single sheet of peel ply. Add more pictures of the seatback and F-22 and F-28 to the chapter 4 page. 4
Thu 12/23/99 4 Rough cut F-28 and the outside of F-22 using the band saw. 1
Wed 12/29/99 4 Rough cut the leg holes in F-22. Began sanding all the rough edges of F-22 and F-28. What a pain this is. To do the rough cut of the leg holes I tried a hacksaw blade. No way - this would take forever. Next I tried using cutoff wheels with the Dremel tool. This worked some but I went through my last two cutting wheels and only got through about 5%. Then I got smart and dug out the new sabre saw I received for Christmas. Much quicker. I used 36 grit sandpaper to start sanding the edges smooth. There must be a better way. 2
Thu 12/30/99 4 Finished shaping F-22 and F-28. Cleaned up the shop. It was getting a bit cluttered with all the work on the two bulkheads. Began cutting the foam for the instrument panel. Shaped the upper and lower portions. 6
Fri 12/31/99 4 Finished cutting the foam for the instrument panel. Used 5-minute epoxy to glue the pieces together. Did the layup on the aft face of the IP. This included slurrying the face, applying two layers of BID and one of UNI (above the leg holes). Applied a sheet of peel ply over the whole face. Knife trimmed all the holes after a fews hours of drying. Had to interupt my New Year's dinner for this. 6
Sat 1/1/00 4 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 web site. 7
Sun 1/2/00 4 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. 5
Mon 1/3/00 4 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 overnight. 6
Tue 1/4/00 4 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. 1
Thu 1/6/00 4 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. 1
Sat 1/8/00 4 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 hardpoints. 2
Sun 1/9/00 4 Trimmed and sanded the final layup for the IP stiffeners. 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 inserts. 7
Mon 1/10/00 4 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 the hardpoints. Cleaned up the shop a bit. 2
Wed 1/12/00 4 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 glassing. 2
Thu 1/13/00 4 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. 3
Sat 1/15/00 4 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! 2
Mon 1/17/00 4 Did the layup on the aft face of the forward landing gear bulkhead. Two layers of BID and one of UNI. Added peel ply. 3
Tue 1/18/00 4 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. 1
Sat 1/22/00 4 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. 8
Tue 1/25/00 4 Removed all the peel ply from the landing gear bulkhead and all the firewall pieces. Trimmed and sanded flush the fiberglass. Marked and drilled the 3/16" holes for the blind screws in the firewall. 2
Sat 1/29/00 4 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. 5
Sun 1/30/00 4 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. 2
Chapter Total 107