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Dave's RV-10 Build Log
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Date:  10-2-2017
Number of Hours:  4.75
Manual Reference:  
Brief Description:  Windscreen Fairing; Window Edge Filler

Sanded down the coat of epoxy painted on the windscreen fairing last Friday.

The cured epoxy had a lot of surface air bubbels that needed to be sanded out. Did this by hand with 80 grit, then 120 grit, then 150 grit paper wrapped around a 5" piece of "pool noodle".

Sanded the bottom edge of the fairing at the electrical tape using a 5" random orbit sander with 80 grit paper to get down to the tape. Removed the tape and then feathered the edge to the aluminum skin using the random orbit sander with 120 grit paper. Finished up by hand sanding with 120 and 150 grit sandpaper.

Mixed up 2 pumps of epoxy with fast hardener and about 30-40% acetone as a thinner in order to reduce the size of the air bubbles and allow a thinner coating to be painted onto the fairing. Still got small bubbles but the thinner epoxy painted onto the fairing didn't drip as much.

Masked off the outside of the door and rear windows using electrical tape. Sanded the shallow gaps around the edge of the plexiglass between the window and the cabin top window flange and the fiberglass top close to the windows, and cleaned the areas with alcohol. Mixed up a very thick epoxy-micro putty with enough micro that the mix no longer looked glossy. Applied the epoxy-micro to the gaps with the flat trimmed tongue depressor used for mixing, then used a plastic scraper to level the epoxy-micro and remove the excess.
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