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N115AR 601XL - FOR SALE
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Date:  8-20-2008
Number of Hours:  4.00
Manual Reference:  
Brief Description:  Creating a mold for the saddle

Time to tackle the saddle. Not having too much experience with fiber glass parts... I had to improvise quite a bit. I took a piece of foam and formed it to the shape of the saddle. My design will wrap over the rear top skin and under the horizontal stabilizer. Forming the part took me for ever. What was worse is that once finished I realized that I had not provided enough clearance for the elevator control cable.... so I had to add more foam. I am not sure how the final product will look... it will sure be original. Given the fact that I will be working with polyester resins and MEK, I had to figure out a way to seal the foam. I melted some wax and then just took a brush and applied a couple of coats over the foam.
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Foam cut to a preliminary shape

Foam cut to a preliminary shape

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Saddle sanded down to shape

Saddle sanded down to shape

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Aplying a wax protective layer

Aplying a wax protective layer

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