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Dave's RV-10 Build Log
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Date:  3-2-2018
Number of Hours:  4.75
Manual Reference:  
Brief Description:  Air Box to Cowl Connection Fab

Cut out the inside of the foam block to create a smooth transition between the cowl inlet air opening and the filtered air box inlet using a 24 tooth hack saw blade. Did a bit of light sanding of the finished opening.

Removed the top and bottom cowl. When dropping the bottom cowl out of position, a piece of the foam at the top back broke off due to the foam being a bit too long. Had to purchase a hot glue gun and glue the piece back into place before fiber glassing.

To do the fiber glassing, decided it would be best to position the bottom cowl on the floor with the inlet facing up. This way the fiber glass will be hanging down into the inlet with gravity assisting the installation, rather than having gravity working against me with the layer on top wanting to fall down.

Decided to use a "pre-preg" method I learned at the EAA Sport Air composite workshop. This involved placing two layers of fiberglass into a gallon zip-loc bag, pouring epoxy onto the fiberglass and then closing the bag and spreading the epoxy into the fiberglass with a squeege spreading tool from the outside of the bag until the fiberglass was fully sturated, then squeeging any excess out to the sides of the bag. Then cut the bag around the fiberglass. I could then peel the top layer of the remaining plastic off the fiberglass, and lifting the epoxy impregnated fiberglass off the lower plastic was able to drape the fiberglass into the inlet and easily place it.

Layed up 4 layers of 6 oz. fiberglass with the weave on a 45 deg. angle. Used 4 layers rather than the plans rrecommended 3 layers since I only had 6 oz. fiberglass instead of the plans call out of 9 oz. fiberglass. The first 2 layers were placed at the top and bottom of the opening, whicle the second 2 layers were placed at each side. The fiberglass was wrapped around the front inlet, and allowed to hang down at the back. Inflated a balloon inside the fiberglass and left it to hold the fiberglass against the foam while it cures.
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