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Date:  6-22-2014
Number of Hours:  4.30
Manual Reference:  
Brief Description:  Cut NACA foam

Make bottom sanding templates. Made one just square on the inside to get an idea where the bottom/sides transition from flat to curved.

Back to the hangar, and cut a slot in my table to accommodate the Instrument Panel. Then Viki and I moved the fuselage back onto the work table, inverted.

And now we hit a point where I just can't do as Nat suggests, nay, ORDERS! The NACA duct is supposed to be created from 3lb Urethane foam. I have a sheet, and can see it is really easy to shape, and cheap, but I just can't use it. There will be none of this crappy florist's foam in my airplane. The only builder I know that has bucked the crappy urethane is Drew Chaplin, Cozy Midnight #1200. He used a spare seatback ASS shipped him, and regrets it not. He did use some urethane between the AFT MLG Bulkhead and the firewall and regrets it. When I helped him with the bottom layup I'll be doing soon us 'elfs' weren't allowed to TOUCH the urethane. He reserved that challenge for himself. Drew suggested a router table to cut the foam flat, meaning you don't have to worry about joins, micro and the less-easy-to-shape PVC foam. Rather than PVC, I ordered a sheet of 1" H45 Urethane, and it worked good. To make it easier to shape the plans have you place a block of 2" near the rear, and 1" forward, to make an easy, vertical join. I took a harder path.

The FAQ report an unsightly dip if you cut the foam as per the plans, so I have 3/8" H45 28" forward of the FWD MLG Bulkhead, (note my seatback and landing brake are 1" aft of the plans position). On top of that is 1" H45, 18" forward of the same point.

Cut out required ply and foam for between the bulkheads on the right side.
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Cutting a slot for the IP

Cutting a slot for the IP

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Viki departs after transporting the Spodplane

Viki departs after transporting the Spodplane

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Will this work?

Will this work?

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