Continued to prep for fiberglass yesterday. I fabricated the two extra foam blocks per a suggestion from John Bender. Attached then waxed the layer of cellophane packing tape with a mold release wax (5 coats). (I have described the extra foam blocks in a previous post. To insert the lower foam block, the hydraulic strut has to be removed.) Also waxed the two added foam blocks after taping them.
UPDATE: At the aft end of Ply #1, where the template comes to a point, it is a good idea to mask about 1/4" below the line on the canopy skirt. Will keep the canopy skirt clean, yet allow you to position ply #1.
Added a dab of silicone grease to the top of the canopy frame pivot bolt.
Time to start the fiberglass. This is a new experience for me. I am using the West Systems epoxy and hardener. See the photo. DO NOT use the fast hardener. It sets up way too fast. In fact, the fast hardener SMOKES as it sets. The slow hardener is much more manageable.
To cut the plys to shape, the rotary cutter worked very well. You have to be very careful how you handle the cut plys. They can change shape very easily if you stretch them. Cut a small piece of fiberglass and play with it. You will find you can handle the ply in the direction of the fibers but not in any other. I also made 5 copies of the ply template at Staples, thus, was able to reshape each ply just before installation using templates #1 thru #5.
To mix the epoxy, I bought a couple of squeeze bottles at Wal-Mart and used Renee's kitchen gram scale. Mixed it 5:1. Much easier to dispense the epoxy and hardener from the bottles as opposed to the original containers. BUT, I am going to find the West System pumps. Foolproof, as long as you read the instructions, per a chapter member. 1 pump on each.
After mixing a batch of epoxy and flox, I filled the shelf. Coated the bonding surface with epoxy. Then placed the first ply on some 0.7 mil plastic painters dropcloth. (A little stiffer than Saran Wrap). I placed the template under the dropcloth so I knew if I was distorting the glass form. Wetted it out, covered it with another piece of dropcloth and then used a squeegee to remove the excess. The first time I tried to place ply #1, it distorted terribly. It ended up in the trash can. Recut ply #1 and the 2nd time went well. Was able to position it without much distortion. The guide marks under the clear tape were a lifesaver.
Placing plys #2 thru #5 were simple, as you place them dry and then wet them out using a 1" paint brush.
Concluded today's learning experience by adding a piece of peel ply cut just a bit larger then ply #1. The right side will be MUCH easier. Will be busy with home projects the next couple of days. Right side is next.
Time Today and Yesterday - 7 hours
