Month: January 2020

Cozy MKIV – January 25, 2020

Trim, sand, and vacuum the aft heat duct.

Cut 2-ply BID cloth @ 45 deg orientation and a piece of peel ply to cover the layup.

Workshop temperature 24 deg C and 40% humidity.

A batch of epoxy was mixed using 188g resin and 72g hardner.

Epoxy was brushed onto the top glassed portion of the heat duct.

A batch of micro was mixed and applied to the foam surfaces of the heat duct.

A small batch of dry micro was applied where the top surface meets the ramp at the rear of the heat duct.

Two layers of BID cloth were applied on with epoxy, followed by peel ply.

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Cozy MKIV – January 18, 2020

The areas where the birch plywood inserts are to be installed were sanded with 36 grit sandpaper.

7-ply BID cloth was cut for each of the four inserts. A 1″ overlap was used except for the insert where the step will be attached. For this insert a 1.5″ overlap was used.

1″ overlap
1.5″ overlap
7-ply BID cloth

Workshop temperature was 24 deg C and humidity 38%. A batch of epoxy was mixed using 170g resin and 64g hardner.

The four sets of ply were wet out with the epoxy then a small batch of wet flox was mixed.

The flox was applied to each of the plywood inserts and the inserts were positioned in place with flox filling any voids.

Wet Flox

Lastly, each of the inserts were covered with the 7-ply layup.

Front Right Insert
Front Left Insert
Front Seat Area
Back Seat Area
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Cozy MKIV – January 11, 2020

Using a hack saw and file, the excess material from the four shoulder harness support tabs were removed and made flush with the front seat. A small and thick batch of flox was mixed and applied over the slot area to fill in any cavities and smooth out the surface.

Four 1/4″ thick birch plywood inserts were cut and shaped to fit against the longerons as part of the safety belt anchor point assemblies. The front anchor points are located 5″ forward of the point at which the bottom longeron and front seatback intercept on both the left and right sides of the fuselage. The rear seatbelt anchor points are located 8 3/4″ forward of the forward landing gear bulkhead.


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Cozy MKIV – January 4, 2020

Workshop temperature was21 deg C and 46% humidity.

A small batch of flox was mixed using 16g resin and 6g hardner along with some flox.
The four aluminum tabs were flox’d in place.

Four 1/4″ holes were drilled (and countersink) into the aircraft step.

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