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Date:  8-6-2010
Number of Hours:  5.00
Manual Reference:  
Brief Description:  Wing Root Forward Fairing

I continued the process of making smaller pieces of aluminum out of larger pieces. It turns out the LP Aero windshield isn't exactly symmetric, and the two forward wing root fairings are fairly different, the right one being almost linear at it's inner edge and the left one requiring curves to optimize the seal. It took several tries on each fairing to successfuly accomplish the various elements of fit: overlap with existing nutplates and the fuselage channel, screw hole center-edge distance, close approximation of the leading edge, and screw holes which don't promote scalloping, to name a few. I made the fairings out of .020 inch 2024-T3 after using clear template plastic as an initial pattern. I used a bend roller to make the iniitial leading edge bend, and additionaly bent the leading edge over some 1 inch pipe in order to get a tight fit. I also slightly elongated the holes nearest the bend towards the bend, their location determined using a homemade hole-finder and drilled with a #40 dill, prior to drilling with a #28 bit, which further tightened the fairings up.
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Failed attempts.

Failed attempts.

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Right forward wing root fairing.

Right forward wing root fairing.

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Left forward wing root fairing.

Left forward wing root fairing.

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