Category: Parts & Services

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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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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