Canopy Installation, Part 6

Forward with the alternate canopy fiberglass trim piece....almost per Van's instructions, but with a few of the EAB/I'd rather do it my way deviations.

One of the first tasks was to cut out the full size templates provided with the plans to create the components of the trim piece.  I elected (deviation) to mount the templates on poster board to give a firm foundation upon which to lay up the fiberglass.  One of the problems many builders experience is the sag in the whetted fiberglass over the non-uniform surface of the forward canopy frame where it mates to the forward fuselage.  The stiffened templates are an effort to minimize/eliminate the sag and the requisite filler required to make it "all purdy."  The first shot below shows the right side with the template taped into place.  There is electrical tape trimming the intersection of the template with the canopy bubble and clear shipping tape covering every square inch of the template.  Finally, there is some butcher paper masked onto the surround area to minimize the effects of any accidental spills of the epoxy resin.

And speaking of resin, I am continuing to use West Systems epoxy, the 105 resin and the 209 (extra slow) hardener.  It is very nice stuff and very simple to work with and I do not even perceive any fumes.

Up next was the cutting of the fiberglass cloth into the 5 layers as prescribed by Vans.  The use of a rotary cutter and straight edge simplifies and makes short work of a somewhat tedious task.

Five plys of fiberglass all trimmed to size and ready to go.

 Mix up the epoxy resin (3.7 parts resin to 1 part hardener, by weight) and we're off to the races.  In the heat of the battle, I did not take any photos.  The shot below is of the glassed 5 plys and a layer of peel ply or dacron fabric.  Use of the peel ply makes a huge difference in the quality of the finish.  I will still need to do some heavy resin/micro slurry build up of the low spots, but the surface is so nice to work with after the peel ply.

The next picture shows the peel ply coming up off the cured resin.

 
And the finished work prior to filling...

I forgot to mention the last of the prep work required before laying up the fiberglass.  That involves spreading some good quality car wax (I used Turtle Wax) over the areas to be glassed to facilitate easy removal when the part is cured.  I used 3 heavy coats prior to applying the glass and resin.  I will have to comment on the success of my procedure later as the fiberglass fairing is still resting in place.  I will perform the resin/micro filling of the fairing where it sits in place for an easier approach to the sanding.

 The second piece of the fairing, on the pilot side of the fuselage.

The last piece of the fairing is the long straight piece that connects to the sides.  Below, the area is taped and waxed prior to glassing.

Again, no pix from the glassing process, but the third of three pieces of the fairing is now drying with the peel ply on top.  The micro "cake frosting" process will happen next...when the microballoons arrive in the mail.