jpolenek Posted July 8, 2008 Share Posted July 8, 2008 Here is a technique I used for my wing attach depressions. Not sure if other builders are already doing this or if I'm the first, but it made sense to do it this way, as I couldn't figure out how to avoid making a big mess of it following the plans' method. So this was my process: 1. Make a plug from Styrofoam. This way, it's very easy to get perfect radii using a router, sander, etc. 2. Prep the foam with medium-dry micro slurry to fill the cells, then do the 2-ply BID layup over the foam. Peel ply where possible. 3. Use jig and router to cut a depression at the required location in the wing that will fit the insert. 4. After cure, remove peel ply, scratch sand the insert and micro it into the depression. (Use generous amounts of micro to fill all the voids, thick enough so it doesn't run out but runny enough to enable the excess to squeeze out and allow the insert to sit at the bottom of the depression.) 5. After cure, trim the insert flush with the surrounding surface of the wing. (This is one of the many times when a Fein tool is REALLY handy.) 6. Remove foam from inside the insert and scrape the sides down to the glass. If you remembered to micro-prep the foam before glassing, and it was fairly dry micro, then it will scrape off nicely right to the glass. A 4" screw with Vice Grips for a handle works beautifully as a rasp. A bend in the screw enables it to get into the corners easily. 7. Use a small strip of coarse-grit sanding belt (e.g. 1"x4") and sand the inside of the depressions to smoothness. The method takes a little more work than the plans' way, but the final result is well worth it if this type of detail is important to you. Joe Polenek Quote Joe Cozy Mk IV #1550 Link to comment Share on other sites More sharing options...
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