BOOK END
.....The last practice part that you will make before starting on your
airplane is a book end. It takes three layups to make the book end
and involves most of the operations that you will need to learn, to
build your airplane.
.....Cut the 3 blocks
of green urethane foam (2lb/ft3) as shown.
Nail them together.
.....Cut three plies of BID as shown.
.....Mix 4 oz. of Safe-T-Pox epoxy; using about 1 oz, make a small batch of micro slurry and coat the foam as shown. Make dry micro from the leftover slurry and a small radius with it as shown.
.....Lay up the first ply of BID as shown.
.....Using plain epoxy (no micro), lay up the other two plies and allow
to cure. Note how the 45° fiber orientation allows the glass to lay
down completely into the small radius.
.....Knife trim along the foam edges. After the first layup has cured and the edges have been trimmed, the thicker foam block is carved and contoured as shown.
.....Put a generous radius on the foam edges and sand the! II wi de gl ass edges dull for gl ass to gl ass bond. Use your wire brush to rough out a depression in the middle of the block. Finish smoothing the depression by rubbing it with a scrap of green foam. Radius the corners of the depression. Blow or brush all of the foam dust off the surfaces.
.....Cut three plies of BID as shown.
CONTINUED ON NEXT PAGE
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