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Building Integrity
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Date:  8-7-2015
Number of Hours:  6.00
Manual Reference:  Section 2
Brief Description:  Lower Cowling cooler mod

It all starts with foam doesn't it.... So I hot glue gunned a piece of Blue foam to the bottom of the lower cowling, pleased to find that it was the PERFECT thickness of foam that I needed which means 1 piece and done. After removing the cowl I brought it home to tackle the glass work. I decided to use a foam core poster board from Hobby Lobby for the template. This was a great idea. I cut through the section NOT completely using a razor. This allow me to fold it in half and perfect the airfoil shape on one side. I then folded it over and traced the line onto the other half, razor cut it, then sanded both to be a perfect match. Awesome profile!
After using it to trace the profile into the blue foam, I started cutting and sanding. The blue foam is a heck of a lot harder to sand than other foams, but the narly 36grit was up for the challenge! After coming to a "good enough" sand job, I laid up 1 ply UNI and 1 ply Carbon over the foam. NO MICRO slurry since I'll be digging out the foam later. I first was going to tape over the foam, but no tape wanted to stay put, so I just removed it. After cure, I'll be adding at least 1 more ply on the underside for strength. Not excited about foam removal but whatever...I'll go buy some corn at the pump and use that :)
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Starts here

Starts here

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Template

Template

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Template in place

Template in place

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