Chap 1-3
Photo Gallery

Cozy Construction Chapters.


Chapter 21 - Strakes, Fuel & Baggage

Started 02/18/2011 finished 09/25/2011 Hours worked this chapter :142

Last big glassing chapter.

Fabrication of parts

With the part all cut out and labeled, glass with peel-n-ply and the orientations are marked as well. The large number of part and the left and right tanks having the same part but with different angles it will help during assembly.Here's the bottom skins glassed with peel-n-ply sheet material. In the lower corner you can see the sump opening.

Set the bottom skin with flox of the back end of the bulkheads (33, 57)to make sure the are true and fixed before moving forward to the leading edge.

In this picture you can see that they other bulkheads are not floxed yet.


Now that the back end of (33, 57) are cured I can bend up the bottom skin without any concern of the bulkheads moving. Worked great.

Here you see the bottom skin and bulkhead 33 & 57 floxed in place. I did this in stages first I floxed the bottom skin at the spar joint and let it cure, next floxed the two bulkhead at the spar joint, at the stage you see in the picture I've put in the jig board and clamped it in place with sand bags to cure.Co-pilots side with major bulkhead in place test fit

All bid tap completed second coating of epoxy required to seal inside of fuel tank.Cutting rough baggage access openings

Baggage openings refined glass support lip on fuselage and added bid tape on the inside of baggage, epoxy on the bottom part this will be finished when the top skin is installed. I wanted to make sure I had the bid tap in the correct location to prevent and leaks into the baggage bay. Worked out just as I hoped although you have to be limber and take your time. I cut a brush hand off to make it shorter to fit into the bay.

Here you can see the pour foam that fill the space next tot he spar, this is done to keep C of G correct.Vent line is in place and you can see the location nails used to location the top skin. I wanted to make sure that during the install it did not slide around and the flox stayed put on all bulkhead and joints are good the sealed.

The white is silicone plug to keep out the epoxy. When ready I just pick out the plug and the threads are clean and ready for the drain valve.

Tea Bag strainer used to cover the sump opening in the fuel tank

Sanded the edge of the strainer and floxed it in place.

View of the vent line and sump opening with strainer

Staying tight to the fuselage hides the vent line exit thought the fire wall. 

Sump fuel line floxed in place before sump addition.

Fuel sending unit plug.

Top skin floxed in with sand bags and duct tap to hold fast.

OD bulkhead opening before installation

OD floxed in place

I change the fuel valve set up so that I can control remotely two valves with push/pull cables

Here's the valve manifold installed

Block and tackle set up to flip the airplane

Here you see a saw horse with office chair caster on so that I can roll the airplane into my garage once turn over.

Ready set....


Pull Pull... Hold her steady boys.

And there you go all done.

Rolled it in, now set up to do the fairings work and the sump tank.

Glassing over the foam form for the sump tank left side

Same process on the right sump tank.

Pour foam used to fill in the fairing of the sump tank

Sanded fairing sump tank shown here

Glass the front part and pour form the back section.

Removed the form around the pour foam


Glassing the top after bottom fairing is finished.

Leading edge shaped and glass applied.

Used a long sanding block to get a true and straight edge before glassing.


Form created out of cardboard and packing tape, set to fill with pour foam for top fairing.

Pour foam close-up shot

Top fairing glassed look from front

Picture from the firewall end here you can see the fuel vent line.

Used a glove to see if the pressure would hold over lunch time, just for fun.

Here you can see my water column with lots of testing.  Found a leak in the fuel line fitting on the left wing.

Keep track of the barometric pressure and air temp. to make sure the fuel tanks are air tight.  Three tests later all is good after 5 days pressure test.Here you can see the space between the wing root and the fuel strake.

Getting tight in the workshop.

Filling in the space between the wing root and the angled fuel strake left side

Same for the right side, here you can see the wood spacers used to keep the alignment correct and the spacing.


Home | Chap 1-3 | Chap-4.htm | Chap-5.htm | Chap-6.htm | Chap-7.htm | Chap-8.htm | Chap-9.htm | Chap-10.htm | Chap-11.htm | Chap-12.htm | Chap-13.htm | Chap-14.htm | Chap-15.htm | Chap-16.htm | Chap-17.htm | Chap-18.htm | Chap-19.htm | Chap-20.htm | Chap-21.htm | Chap-22.htm | Chap-23.htm | Chap-24.htm | Chap-25.htm | Interests | Favorites | Photo Gallery

This site was last updated 01/10/17