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Date:  2-26-2014
Number of Hours:  2.00
Manual Reference:  
Brief Description:  F28 bulkhead - preparation

Step one was checking the remainder of the templates I prepared for the mockup. All OK, except F28, which I didn't make for that.

Plans have you start on the seatback, but that is large, and more complicated, and has flox corners, and 4 builders have reported screwing it up and throwing it away, meaning they have to wait for more foam before starting the build. I started with F28, which is probably a more critical part, but if I don't like the look of it in CH06 I'll throw it away, and I'll have plenty of spare materials to make a new one.

Plans also tell you to make F22 at the same time, but I'll do it separate and later, as it looks a little more complicated.

Plans let you build it low, or 1" higher for a rounder shape. I'm worried about weight up FWD, so will build it low.

The FAQ of the Cozy Builders email list say the standard position for F28 (5.9" from F22) does not leave enough room for the plans canard. F28 should be at F.S. 28.35 instead of F.S. 28. As such it supposedly needs to be 0.5" wider. [When trying to install in CH06 the result was almost 0.5" too large, so this may be a crock, or I added the 0.5" twice???]

FHC plans fit a doubler later for the hinge mount. Will fit now as per F22 doubler method. Should have made the longeron cutout smaller due to the mounting angle, but just mounted 0.05" outboard. Doubler is 1" wider than plans, may use Catbird style hinges.

All cut out with box cutter knife and electric coping saw. All fibreglass cut out with electric scissors
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F28 and doublers marked up

F28 and doublers marked up

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Cutting out F28

Cutting out F28

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Cutting out fibreglass for F28

Cutting out fibreglass for F28

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