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Michael's Cozy Web Site
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Date:  11-15-2009
Number of Hours:  4.00
Manual Reference:  Step 4
Brief Description:  Assembly of Foam Cores

OK. I went back to step 2 and camped there for the last 3 months. I spent an undocumented amount of time. I studied. I measured. I studied some more. I had Nancy study. She measured. I ended up cutting the jigs out a little and using foam blocks glued to the jig to align along the WL mark to keep vertical. I did this with the FC4 and FC5 in place. I used a laser line level to "draw" a line. I used markings on each opposite wall to keep my reference. I also leveled at the trailing edge using tygon tubing and a metric yard stick. I have it level to the nearest 1 mm. I also measured the angle of the shear web face. It should be 7.09° from the trailing edge. I was able to get it to 7.0°. I couldn't measure any more precise.The joint between FC2 and FC3 was not true and did not match. The overall length was about .125 in short, so I used foam to fill in the gap and get the correct length. Nancy and I micro'd this joint together.
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