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Jims RV-8
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Date:  3-20-2018
Number of Hours:  1.00
Manual Reference:  
Brief Description:  Console storage - flange work

I pulled the flange off of the aluminum foil and most of the foil came right off... except two parts of foil that you can see the scraping and sanding on pic #1. The good news was that the sharpie lines for the borders transferred to the fiberglass layup so cutting along the lines with the cutoff wheel and sanding was easy. There are some very small bubbles in the layup, but structurally sound for a console flange.

I dropped in the flange for a test fit after I did a rough cut and sand and it fit really well. Still needs final cutting and sanding but I am happy with how flat and level it came out. I then leveled the console to fit better on the flange. You can see on pic #3 how I formed an inner bevel around the top of the console where it meets the flange. This was done intentionally as that bevel will be part of a glass fillet to connect the flange to the console without extending outward too far as I need to keep the clearance from the frame as the fillet can't interfere with the metal frame.
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raw flange

raw flange

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preliminary cut and sanded flange

preliminary cut and sanded flange

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initial fit of console on the flange

initial fit of console on the flange

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