06/29/2009 Started on the nose cone door. I marked up the door dimensions and layed up 3 BID and placed on the top of the nose to take shape. The nose was covered by tape. 06/30/2009 I took the nose cone door off and found large bubbles had formed which disfigured the shape. This part was scrapped and a new one made. I replaced the sealing tape on the nose foam to make sure I got a good surface 07/01/2009 This door turned out great! I layed up 3 layers of BID around the edges to form the door lip. I also cut out the ballast door in front of F0. 07/02/2009 I trimmed the door and used it to draw a pattern on the foam. I used the dremel and scored the foam to a depth that would allow the door to sit in the foam flush. I sanded all corners down and layed down 2 layers of BID over the nose. I placed the door on saran wrap into the recess to keep its shape. 07/03/2009 I cut out the door leaving a 0.8" flange for the door to sit in. I then cut the top off and prepared it to be covered by sanding the inside of the door to allow the glass to glass bond on the door lip. I layed up 1 layer of BID overall using flox at the corners. I layed up 2 extra layers of BID at the lip to reinforce. I then floxed the top back onto the nose. I taped the inside corners, well, almost all of them. I could not get to the right front, so I will have to do that tomorrow. 07/04/2009 I taped the outside joints and installed the F22 brace. Still require top layup and the inside front corners. 07/05/2009 I layed up the top lay up for the torsional brace to F22. 07/05/2009 I layed up the top lay up for the torsional brace to F22
