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Date:  1-24-2018
Number of Hours:  2.00
Manual Reference:  24-04
Brief Description:  Front seat thigh supports

Remembering how hard it is to trim to concave curves with the ubiquitous multi-tool, took a leaf from Drew Chaplin's 'how-to' videos and decided to trim the thigh support ribs with a template and router trimming bit. First attempt with 3mm MDF was too easy to damage, another with 1/4" marine ply made it an easy but messy job. Highly reccomended technique for when you you to produce a number of identical parts. Not quite sure I could be bothered if it was only one part. Rather than hand held I had the router mounted on my saw table, and my template could be the same size as the finished part, as that is the trimmy bit I have. I attached the template to the rib blank with nails and ground away. Not many good pictures, because after the preparation each rib took less than a minute to trim perfectly!!! Thanks Drew!

Was somewhat disheartened to learn from the plans that it does not make sense to actually install the ribs untill the armrests are in, but was also impatient to sit in the aeroplane properly, so spread packing tape around liberally, then hot glued the ribs to the floor, and hot glued the thigh support to the ribs and floor. Spread the driest micro I have achieved yet into the slots, then 1 x BID overall. Only did the pilot side, as I want to sit!
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Trimmy, trimmy, but a new way to trimmy, trimmy

Trimmy, trimmy, but a new way to trimmy, trimmy

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Seats labelled carefully to indicate intended function

Seats labelled carefully to indicate intended function

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Trowelling in dry micro, tired fingers

Trowelling in dry micro, tired fingers

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