7/20/2008
I hate fiberglass. I noted it in my written log. I hate it.
Guess what I did today! Yeah, it was time to figure out how to 'glass the windscreen in place. The flox filler was so much more pleasant to do than this. I started by removing the Dacron and tape from the filler layer I did yesterday.
Then I laid down two layers of tape, the first green, and the second yellow. This will allow me to see if I'm getting close to sanding thru the tape to the plexi. I also found something to use as a sanding drum. It's not quite the perfect radius, but when squeezed a little bit, it's nearly spot on.
After sanding for a while, I had a pretty smooth surface, and the curve was looking good. I then added two layers of red tape to mark the critical line...where the plexi will begin to be visible above the fairing.
Nothing to do now but get started on the fabric. I used 6oz. fiberglass. Here's the stuff, ready to get started.
I used the method pretty well spelled out in the instructions, and started with a 1/2" strip, working my way to the 7th layer, a 2" strip. I used at least two pieces per layer, varying the lengths so no ends would meet at the same place.
Then I masked off the area to be 'glassed with several layers and varieties of tapes.
The process of putting all seven layers of 'glass on at the same time isn't that difficult, but the chemical reaction from the epoxy and flox is interesting...it gets REALLY hot after a while, and becomes unusable at that point as it starts to harden quickly. I had to mix up three batches to get thru the layers, and didn't have time to take pics along the way. Here's the 'glass all laid up, with peel-ply in place.
That Dacron material is really something! After about two and a half hours, I went back out to peel it off, and it leaves a very smooth surface, but I still have plenty of sanding to do to get it ready for microballoon filler.
I cleaned up the top edge with a knife, and will use filler to make the transition from the plexi to the 'glass.
I'm glad that part is over with. I have plenty more 'glass work to look forward to, but that's a ways out.
3.75 hours