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Cozy Experimental Aircraft Update – September 10, 2018

After sanding the bottom of the fuselage between the landing brake and the forward landing gear, it became obvious that there was a spot on each side of the NACA scoop that dipped in towards the centre of the fuselage. I have added material to build both areas up before any further sanding.

Foam pieces were cut large enough to fit over the two dips in the fuselage bottom. A batch of micro was mixed – workshop temperature 25 deg C and humidity 58%.

The foam pieces were micro’d in place and weights added on top of them while they cure.

Cozy Experimental Aircraft Update – May 19, 2018

Taping the front fuselage section floor joints:

Cut enough cloth to make two 17″ x 2″ pieces of BID tape and two 9″ x 1.5″ pieces of BID tape.

Workshop temperature was 25 degC and humidity 53%.

134g resin and 51g hardner were mixed together.

The BID cloth was wetted with the epoxy using a squeegee.

The areas to be taped were wetted with the epoxy using a paint brush.

Some of the epoxy was poured into a smaller copy and flox added.

The flox was applied to the joints in the areas to be taped. The fuselage sides, forward of the instrument panel, were taped to the floor. Bulkhead F22 was taped to the floor.


Glass bubbles were added to the remaining epoxy and the micro slurry was used to fill the gap between the forward landing gear bulkhead and the floor.

Cozy Experimental Aircraft Update – March 12, 2018

Glassing the Cozy MK IV floor

Workshop temperature was 25 deg C and humidity 38%.

The entire surface was covered with micro slurry then a batch of dry micro was mixed and used to fill in any holes and to make a generous radius in all corners.

Two plies of BID cloth at 45 deg orientation were applied to the floor with 1″ overlaps and the selvage removed.

A third ply of BID was applied from the seatback brace aft at 45 deg orientation.  Dacron was applied to the surfaces where the fuselage bottom will mate with the sides and the bulkheads.

Final quality checks completed before we left the layup to cure …

Cozy Experimental Aircraft Update – December 27, 2017

Permanent installation of the seat brace and the heat duct.

Outside air temperature was -20 deg C and the workshop temperature was +25 deg C (humidity 32%).

The seat brace/duct assembly was positioned in place and a marker was used to outline where it mates with the instrument panel and seatback.

62g resin and 24g hardner were mixed with flox and applied to the instrument panel and to the seatback.

The seat brace and heat duct were placed in position and 2 x 4s were used to clamp the assembly in place during cure. The bottom of the heat duct was confirmed to be flush with the instrument panel, with the seatback, and with both lower longerons.

Flox was applied to all outside joints and excess flox was wiped away.