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Date:  7-10-2015
Number of Hours:  4.40
Manual Reference:  Step 3 and 6
Brief Description:  Elevator upper skin layup

11.5" wide cloth I had cut will not give required 0.5" overlap. Cut another 2 pieces UND 14 x 57", which leaves a bevelled corner each end. These are wide enough, and the bevel is no on the part, so something between 11.5 and 14" would have done.

Upside down peel ply was a bitch on both sides, go a sore neck now. Had to modify a stippling brush to reach properly.

Poured 2 each of CS-10 and CS-11. Ripped a 40mm pine frame to 21mm thick and cut the outline with a space bit in the drill press. Finished with dremel, file and wood chisel. Farted around for ages lining molds with aluminium foil, on recomendation of the archive. This was a WOFTAM, as I had to pull out the foil for CS-10 #2 and it didn't seem to affect the mould or do anything to the part except make it look better. Bottom of mold just duct tape with foil over the hollow bit.

As the archive also indicated CS-11 was hard to drill for the attach bolts, and the attach bolts tend to crush the weight when torqued up I cast AN3 bolts into the mould, jigged with an aluminium plate match drilled to the CG Products MKNC-12A.

Results:
CS-10 #1 278g, 20.5 x 51mm
CS-10 #2 275g, 20.5 x 51mm

This matched David Pierce's measurements suitably.

CS-11 #1 191g, 53 x 16 x 21mm
CS-11 #2 182g, 53 x 16 x 21mm, small void in middle, and corner blocked by stupid foil.

Slightly heavier than David's, but lots less than Matt's. Hmmm. Got the dimensions right, and all is within the 138g (0.3lb) extra allowed for in the plans. Will leave for now and see how they balance.
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Second ply

Second ply

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Peel plying the transition

Peel plying the transition

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Pouring the CS-11

Pouring the CS-11

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