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Building Integrity
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Date:  4-15-2013
Number of Hours:  8.00
Manual Reference:  ch 25
Brief Description:  Death by fill

Much like the nose hatch, I want straight even lines after the aircraft is painted. This means adding fill to the interior canopy and fuselage now where they meet. Let me tell you, this is what EVERYONE talks about as the WORST part of building a composite aircraft. SANDING to death. Now don't get me wrong, this Z-Grip is great stuff, but when the goal is lines that remind you of an italian built sports car.....it means 10 times longer. Attention to detail. 8 hours of fill, then sand, then fill then sand. My goal here is 1/16" gap under the canopy to accomidate the primer, paint, and rubber seal. This should make a VERY tight canopy. I have the gap so now the rest comes in. BUT here's the death of me. I had my impatience get the best of me not 1 time, not 2 times, but 3 TIMES. yep, a scratched canopy due to slipping with the DA sander. SO now I'm hoping to master the art of scratch removal. :)
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getting the perfect gap

getting the perfect gap

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2 layers of filler

2 layers of filler

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8 hours later and exhausted

8 hours later and exhausted

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