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Mark Weitkamp CX4
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Date:  8-7-2023
Number of Hours:  8.00
Manual Reference:  
Brief Description:  finalized the shape of mold, cut out cloth for lay

I used the same technique as yesterday to apply microballoons and a layer of fiberglass cloth over the forward half of the keel area. I also applied a layer of fiberglass cloth to the forward vertical flat plate, which includes the openings for engine cooling airflow intake and the opening for the crankshaft. some of the flanges on these openings were pretty rough, and I wanted to reinforce and smooth them to better support the fiberglass layup of the actual cowl. I continued to use some old bedsheets and old sailcloth to try out different ideas about how to cut the plies in preparation for the layup. I decided to use square pieces and reasonable angles to economize on cloth used, rather than the extreme 45 degree angle I used on the top cowl. That seemed to lead to a lot of wasted cloth. I cut out three pieces of fiberglass cloth, one for each ply of the layup. And I also cut out a piece of cloth to go in first on the flat front plate, so the outside, most visible layer on that front area will be without overlaps. It seems likely that the width of my cloth will allow me to lay it up uninterrupted from the aft edge to the forward parting surface, but it will take some cutting and overlapping to get it shaped around the air intake openings, and that will cause some overlaps on the flat front plate in those next three plies. If it looks too ugly, I will add a fifth layer to that front flat plate to hide the seams.
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