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Date:  10-13-2015
Number of Hours:  3.30
Manual Reference:  Step 3 & 4
Brief Description:  Assembly NG-30

Inspection reveals F-0 is a fail, dry layup with loads of air underneath, plies just peel off. Boo-hoo. Sanded remaining hardshell, which looks fine. Next one will be wet or bust!

F-5 is fine, trimmed. After experimentation saw through most of the foam in the curve part with a table saw, cuts 15mm apart. Applied a bit of heat and part will follow curve. Drilled some holes for alignment/fixing screws.

Cut glass & peel ply.

Prepped Strut, NG-30, MKNG-3/4, F-0 & F-5.

As an aid to location installed MKNG-3/4 over a tapered 5 x BID pad above and below the strut, like the centre seatbelt reinforcements. Wet out a 5" long bit of BID on peel ply, tapering from 3-6", laid over the strut in an alternating fashion, transferring to the strut with the peel ply, and cutting each edge with Lecky scissors. The peel ply helps it stay in shape, and is easily removed for each ply.

Discovered I can cut peel ply with my new sharp rotary cutter, but is easy to regulate the pressure and cut just the glass or both glass and peel ply.

Smeared around some flox, and fitted MKNG-3/4, and clamped in place to match marks on side showing the position for 6.71" spacing from nose pivot.

2 x BID over FWD face of F-0, peel plied and inverted onto plastic.

1 x BID over AFT face of F-0.

Trowelled a sufficiency of flox onto the FWD edges of NG-30 and placed on F-0. Satisfactory squooge of flox unfortunately obscured position marks. Hmmmm.

Wet out 2 x BID tapes on peel ply on bench, and taped NG-30 to F-0 in four locations. Squooged flox made a perfect fillet.

Notice NG-30 on crooked, reference to c/l, was able to slide it to adjust without distubing anything. Checked it again every time I went near it.

Floxed on F-5, and positioned with plasterboard screws. Leftover flox smeared into curve slots.
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Hmmmm. This could work

Hmmmm. This could work

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MKNG-3/4 floxed over BID pads

MKNG-3/4 floxed over BID pads

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All done

All done

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