Month: October 2019

Cozy MKIV – October 12, 2019

The heat duct transition piece was cut at a 45 deg angle on the square end.

The 1″ hole under the left side longeron was re-opened using an electric drill.

The back edges of the seatback were trimmed and sanded. The peel ply was removed from the front side of the seatback.

3-ply of UND cloth was cut 4″ wide by 13″ long for each of the four harness attachment points.

With the workshop temperature at 24deg C and humidity 58%, a batch of epoxy was mixed using116g resin and 44g hardner. The epoxy was used to lay up the 3-ply UND on each of the harness attachment points such that they ran from 2″ below the shoulder support at the front all the way to the back of the seatback at the top.

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Cozy MKIV – October 9, 2019

Trimmed and sanded the transition piece then removed the inside foam and tape.

Workshop temperature 24 deg C and humidity 55%.

Mixed a batch of epoxy using 138g resin and 52g hardner.

Poured some of the epoxy in a separate mixing cup and added glass balloons. Poured a bit of the micro into a smaller cup and added more glass balloons to make dry micro.

Used the dry micro to fill in any lower areas in the shoulder brace foam then spread micro over all the foam and wet out any mating glass surfaces with epoxy.

Mixed a 2nd batch of epoxy using 110g resin and 42g hardner.

Proceeded to lay up 2-ply BID cloth over the shoulder support and peel ply where required.

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Cozy MKIV – October 7, 2019

Workshop temperature was 24 deg C and the humidity was 58%.

A batch of epoxy was mixed using 30g resin and 11g hardner. Epoxy was applied to 2-ply BID cloth then the cloth was placed around the heat duct transition piece and trimmed to size.

Another batch of epoxy was mixed using 138g resin and 52g hardner. The UND cloth was wet out with epoxy and seven 2″ strips cut to size and assembled into 7-ply.

Wet micro was mixed with some the epoxy and applied to the top of the aft heat duct. A smaller batch of dry micro was mixed using the wet micro and applied on each side of the aluminum tube.

The 7-ply UND strip was applied to the top of the heat duct.

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Cozy MKIV – October 5, 2019

Trimmed and sanded the rough edges at the top back side of the seatback/shoulder support.

Sanded a radius on the forward corner of the shoulder brace.

Trimmed and sanded the headrests.

Vacuumed the sanding dust and cleaned up the workshop.

Cut 2 ply of BID cloth to size to cover the shoulder support.

UND cloth was prepared for the 7-ply heat duct reinforcement.

A transition piece (heat duct to engine) was carved out of urethane foam. The piece is 6″ long and 1.5″ x 1.5″ square at the bottom and 1 7/16″ diameter at the top. The transition piece was covered with black tape so the foam won’t stick to the fiberglass.

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