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Dave's RV-10 Build Log
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Date:  9-19-2017
Number of Hours:  4.50
Manual Reference:  
Brief Description:  Windscreen Fairing; Repair Right Door Strut Mount

Sanded the prior session's fiberglass/epoxy tape on the windscreen lower fairing.
Layed 1 additional layer, plus half of the next layer. The epoxy then started to thicken and set up, so couldn't lay the other half of the layer.

Cleaned up and went to lunch. Then replaced the right side WD-1023 gas strut attach bracket on the cabin top as the originally installed bracket had broken at the side bend to the bottom plate.
Clamped the right door to the left door (both doors open) to hold the right door open and disconnected the gas strut from the bracket. Then removed the 3 bracket attach screws and the bracket came apart into 2 pieces in my hand.
Cut a relief in the door frame edge to allow the new bracket to sit flat on the cabin inside top. Then used washers to fill the space between the middle bracket hole and top, and 4 washers to fill the space between the rear bracket hole and the top. Tightened all the screws and had a well supported bracket.
Reinstalled the gas strut to the bracket.

Counter sunk the rivet holes left open around the doors that were used while gluing the door halves together. Tried to dimple them using the tight quarters dimple set with a rivet puller, but the aluminum material was too thick. So used the mechanical countersink to prepare these holes for installation of flush rivets. Will install the rivets when Kristi is available to help.

The epoxy from the morning layup was now dry, so layed up the second half of the layer from the morning and another complete layer. Mixed the epoxy in a shallow paper bowl rather than in a cup so the reaction wouldn't generate as much heat in the mix and allow for a bit more working time.
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