|
The first step is to cut
the blocks of styrofoam to correct sizes for subsequent wing core
cutouts. I seem to have adjusted the temperature correctly to get the
famous angel hair at the end of the cut. Things still work after a
period of inactivity. Hooray. |
|
I
wanted to get started quickly so I tried to make do with some leftover
styrofoam blocks from before even though they were not
rectangles with parallel sides top and bottom. I am also a
bit of a cheapskate and did not want to have to buy new material. It
might have been smart to at least make the top and bottom parallel. In
fact, this was a bad decision, I should just have sprung for the new
styrofaom. You can see the little "covers" to protect the trough
cutouts during the initial hotwiring. The first time, I didn't try to
use these and had a "rough" edge on the troughs. I learned though and
am now using the "covers". Inicidentally, the aluminum forms were all
made by fellow cozy builder Jean-Pierre ALAGNOUX who has lent them to
me for my use. Good to have a fellow cozy builder nearby. |
|
Same view as above but
BL 118.25 |
|
As was said in the
plans, I had to add a small block to the front for the section between
BL118.25 and BL169. |
|
Here I have made the
initial cuts for the section between BL67.5 and BL118.25. I have also
added the templates for cutting out the electrical access hole. |
|
A little mistake on the
section between BL169 and BL118.25. I cut the access hole correctly at
BL169 but, ... |
|
Incorrectly at BL118.25
where I measured from the leading edge and not from the trough. OOPS.
The hole should be where I made a red filled circle. Will have to add
this hole and fill in the old one. |
|
Finally, all the cores have been cut and most of the
secondary work on the cores has been finished with the notable
exception of the "hollow" root section (the shell with 0.6" thickness).
Have to get a move on it and put these cores together to avoid "hangar
rash". |
|
Once again, (seems monotonous now), a big thanks to
Jean-Pierre for letting me use the foam wing supports that he made.
It's good to have someone building a cozy nearby but even better if
they are a year or two ahead of you in construction!!! Everything has
been leveled in both senses as shown in the manual. I suspect that it
is not that important because we will ensure that it is warp free later
on in the build process. |
|
Here it is after all the sections of the trailing portion of
the wing have been joined. Impossible to take photos during the build
process unless I would have been willing to goop up the camera with
resin and microballoons. A few things to note:
- Even with close attention to detail, the angles of the foam
wing cores were not perfect and needed some sanding to ensure a good
fit.
- The forms are not perfect fits so I chose the top of the
wing as the reference. (e.g. , made sure that the wing was pulled
forward agains the forms)
- The aileron cutout is a pain in the kiester.
- I used tape to keep the micro from oozing out of the joints
where the fit was not perfect.
- All parts were held in place with screws during the initial
curing.
|
|
The aileron cutout is held in place with screws. |
|
The tape to stop the "oozing" problem. |
|
Foam cores pulled forward against the supports. |
|
Lots of scrap (and a few forward wing parts). |
|
Making a few metal pieces. |
|
The "hollow" section has been joined. In the background, you
can see the "hollow" for tool access for the bolts. |
|
Here is the "hollow" for tooled access with the BI ni place
but not yet trimmed. Sure is ugly but it comes clean nicely. |
|
All cleaned up. |
|
All metal pieces in place. I have also added the 45°
angle marks to guide me during the shear web installation.
|
|
Everything set up and ready to put the shear web in place. I
really wish that I had more space to work but .... |
|
The shear web has been applied! What a long layup. It ended
up taking me about 7 hours. I was a little anal about getting things
done correctly. Yes, that is a french newspaper. |
|
Viewed from the other side, things are looking good. |
|
Just putting the leading edge on to see how everything fits.
A few gaps here and there but nothing dramatic. |
|
Everything secured in place with the jigs and curing nicely. |