Category: Cozy Experimental Aircraft Project

Cozy Fuselage

1/4” holes drilled and sanded for front and back seat centre safety harness anchor points.

Opened up the 1/4” holes for the landing gear in the forward and aft landing gear bulkheads.

Opened up the 1″ holes in the landing gear bulkheads for the torque tubes.

1” holes opened up in the front seatback – two for the torque tubes and one for the canopy latch mechanism.

1″ holes in the front seatback

Cozy Fuselage Repairs

This Cozy MKIV project arrived recently from Edmonton and consists of many of the main assemblies such as the fuselage, wings, canard, spar, engine mount, canopy, and nose gear.

The project sat idle in a hangar for a number of years after the original builder passed away. The project has some hangar and road rashes needing minor repairs. First up is the fuselage repairs.

The fuselage interior was cleaned up and vacuumed. The right rear electrical channel still had foam in it so that was removed.

The older and loose foam was removed in the areas that were damaged on the top left of the instrument panel and on the left side of bulkhead F28.

New foam and micro was applied to the areas needing repair.

I cut out the bent and delaminated fiberglass and removed the corresponding foam from the front top left of the fuselage.

Foam blocks were placed in the gap and held in place with 5 min epoxy.

The blocks were cut and sanded to shape.

Micro was applied to the foam followed by 2 layers of BID cloth, and peel ply to the interior side of the repair.

There was a hole on the left side of the nose and no ballast compartment. I filled the hole with foam pieces held in place with 5 min epoxy. Next up I will finish shaping the foam, filling in any additional low areas and mark the location where the ballast hatch will be installed.

Cozy MKIV – February 8, 2020

Installation of the aft heat duct:

Workshop temperature 22 deg C and humidity 35%. A batch of flox was mixed using 54g resin and 21g hardner.

Flox was applied to the bottom of the heat duct and to the fuselage where required.

The heat duct was positioned in place and weighed down with bricks. Excess flox was removed from around the sides.

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Cozy MKIV – February 1, 2020

Removed the peel ply and trimmed the excess fiberglass from the aft heat duct.

Drilled the seatbelt anchor holes out.

Sanded the aft heat duct then cut a hole in the top of the heat duct for the transition piece.

Workshop temperature 20 deg C and 41% humidity.

Mixed 12g resin and 4g hardner with some flox to make a thick batch of flox.

Flox’d the transition piece in place.

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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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