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Building Integrity
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Date:  7-17-2014
Number of Hours:  6.00
Manual Reference:  Section 2
Brief Description:  Cooling plenum foam and UNI

My first attempt to create a cover for the plenum sides was to use Monocote which is used to cover the structure of radio control airplanes. The idea was ok, but the stuff shrunk so tight that it became concave which defeated the purpose. Instead I went to the old trusty foam.
I started with a piece of blue foam for a nice smooth top piece and then added green where complex curves will end up being. These are the times that I'm really glad the fragile green foam exists because it takes so little to shape and sand. I was easily able to contour out the areas that need to clear the oil dipstick. It also made for a very easy way to match up to the flanges by simply pressing a block of foam into the finished flange creating a perfect template for the other to match. I then made sure that every turn and corner was as smooth and gradual as possible to avoid turbulant airflow, however there are some tight turns that can't be avoided so I'm crossing my fingers here.
When it was time to glass, I laid aluminum foil tape over almost all the foam, but left some green where it will be easier to "grind" it out, rather than peeling off tiny shards of tape in tight areas. I also opted for EZ Poxy for better heat tolerance and UNI for my first ply. The UNI has a great ability to take sharp 90 degree turns unlike BID which is exactly what is needed here. After tonights partial cure, I will be adding 2 more plies of Carbon Fiber BID. Keeping the base layer UNI will also keep from the aluminum and carbon having corrosion issues down the road.
*Depending on how the Carbon looks, I may leave it Carbon instead of adding paint...might look very "TUNER" of me. LOL.
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eehhh. Nope.

eehhh. Nope.

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Foam let's go!

Foam let's go!

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Ready to remove and glass

Ready to remove and glass

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