Chin Window Drilling & Cabin Fiberglass
10/11/11 22:50 Filed in: All
Cleaning up a lot of little things. Here is a spot on the body that was bubbled and mostly gelcoat. Ground it out, heat and flattened the fiberglass with a heatgun and pressed it between some angle to straighten . Finally layed up a couple of thin layers to add strength and bondoed to smooth it out.
There were a couple of spots that required this treatment.
Here is where the pre-drilled holes didn’t quite line up with where the floorpan actually fell. Had to drill a new one and fill the old.
FAA required picture of me working. Gotta remember to get more of these. Since I am usually working alone it means getting out the tripod and setting up the camera timer. Coffee fueled build process.
Holes are easy to drill, but each one needs a nutplate and there sure are a lot of them. Here I am drilling and mounting the chin window floating nutplates.
There’s a lot more fiberglass work than I anticipated. This is the lip of the floorpan along the base of the instrument pod. The drilled holes cut through the edge of the lip.
I had to first cut away the fiberglass with the partial holes. A dam was built with packing tape and a tape covered aluminum sheet. Then an thin layer of flox to allow the edge to form, then five layers of cloth. I’ll have to sand a lot of it down, but it should allow for a tight fit with plenty of meat around the holes. It’ll be a lot “taller” than the original lip.
In a few places I had to shim the pan, especially up around the curve of the top of the body. A layer of foam sanded to the correct thickness, then glassed over. To mount the nutplates behind the lip I had to cut a strip of aluminum, mount the nutplate, then rivet it outside the foamed area.