Contouring the floor spacers: Trimmed the 3/4 ” foam to size with the band saw then used a small hand saw to get close to 30 degree bevels and used a sanding block to complete the slope.

Transferred bottom assembly to the work table. Marked the landing brake cutout. Used a jig saw at 45 deg to cut out the landing brake with 1″ radius corners. The fuselage bottom will be given depth and contour by gluing on tapered spacers made from 3/4 “ thick low density foam.

Fabricating the bottom of the fuselage Removed the peel ply from the taped corners where the seat brace & heat duct mate with the instrument panel and seatback. Trimmed and sanded the taped joints. Cut the map pocket to full size in the seatback. Positioned 3 sheets of foam over the bottom of the fuselage …

Cozy Experimental Aircraft Update – January 1, 2018 Read More »

Workshop temperature 25 deg C and humidity 26%. Mixed a batch of epoxy using 146g resin and 56g hardner. Epoxy was applied to the 2 plies of bid (including the peel ply). A small bath of flox was made and applied to all the corners where the heat duct and seat brace mate with the …

Cozy Experimental Aircraft Update – December 31, 2017 Read More »

Removed the 2x4s and clamps from the heat duct and seat brace assembly. Prepared 2” wide tape joints to reinforce the seat brace & heat duct at the bulkheads. Dacron and 2 plies of BID cloth at 45 deg C were placed on a wax paper template.