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Ray Kouns

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Yes, fumes, cancer, don't burn any of the foams except styrofoam. The sticks work well - use plenty of micro and it is a non issure - the sticks are not where you cut em and after you cut them nice and perfect then you cut the the leading edge off and then you glue the odd shapes of core back together, leaving you with fronts and rears for installing the sheer web.


I know this process quite well as i have been doing it for 27 weeks with just two weeks to go. One more spar cap and one more cover and 4 wings done!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!


Once the cores are cut, then it is a seven step process - 4x7=28 and on the first one we didn't realize (read as did not read next sentence in plans) we could attach the leading edge after the sheer web was installed, hence the 29 (27+2)


In three weeks we start the verticle stabilizers.



maker wood dust and shavings - foam and fiberglass dust and one day a cozy will pop out, enjoying the build


i can be reached at



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Dear Ray:


I used 3M Temporary Spray Adhesive to join my wing core blocks together. It is available in a spray can at Lowes or Home Depot. You simply spray a light coating on each wing core block, wait a few minutes until it gets slightly tacky, then push the blocks together. If you screw up, it's EZ to pull the blocks apart and try again.


There are NO ill effects from passing the hot wire through this stuff! No poisonous gases, no bad smells, etc. Jeff Russell at AeroCad told me of this trick and it's the only way to go. Beats mixing sticks and bondo hands down.


Do be aware that the 3M spray is available as "temporary" and as "permanent". Use only the "temporary" stuff. The "permanent" stuff is too strong and will melt the foam on contact.


I've got more documented on my website in the Chapter 19 pages.


Wayne Hicks


Wayne Hicks

Cozy IV Plans #678


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