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The Redheads RV-7A Build SIte
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Date:  9-4-2010
Number of Hours:  2.00
Manual Reference:  Lighting
Brief Description:  Preparing for Landing Lights

One of the issues I had with the original form was that I had to hold the hot-water-soaked 3/32" plywood on both sides while trying to get the band clamps in place on the edges. Just like hanging wallpaper, two hands just weren't enough. So I decided to add a retainer to the new form. To make the retainer I simply cut a piece of 3/32" plywood the width of the form (12 inches) and 5/8" wide. Over the top of this would be a piece of 1/8" x 1" aluminum strip. The added 3/8" height of the aluminum strip would trap the yet to be hot-water-soaked 3/32" plywood between the aluminum strip and the 2x8 forms and retain one end while I then used both hands to form the 3/32" plywood around the forms. Image 1 shows me cutting the 3/32" plywood shim, Image 2 shows me cutting off a section of the 1/8" x 1" aluminum strip and Image 3 shows the partially completed form with the retainer installed.
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Cutting Shim from 3/32

Cutting Shim from 3/32" Plywood

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Cutting Skin Retainer from 1/8

Cutting Skin Retainer from 1/8" Aluminum Strip

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Partially Assembled Leading Edge Form Showing Skin Retainer Installed

Partially Assembled Leading Edge Form Showing Skin Retainer Installed

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