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Dave's RV-7A Builder's Log
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Date:  12-24-2017
Number of Hours:  4.00
Manual Reference:  
Brief Description:  Inlet ramp modifications

I will be the first to admit that after receiving my airworthiness certificate, my motivation for extensive build logging has waned a bit. While I may not log every single build session, I will at least keep things updated so that I’ll have a complete builder’s log when I deem this thing to be “finished”.

This weekend’s project was making two inlet ramp extensions to smooth the transition between the center of the top cowl and the inlet ramps to provide the baffle fabric a surface to seal against. Up to this point I’ve used aluminum tape and a couple of pieces of scrap aluminum to close off the openings, and I’m sure that there is significant pressure loss in those areas. I started by using some modeling clay to make the base for the forms. After covering everything with packing tape to prevent the fiberglass from sticking, I laid up the fabric and left it for the night. When I came back this morning I popped both pieces out, trimmed them up and then drilled them to the cowl. After sanding everything to ensure good adhesion, I used some epoxy and flox to bond them in place.

While that was curing, I mixed up a batch of straight resin and applied it to the inlet ramps themselves to start filling some of the voids. An interesting side note—West Systems epoxy normally takes on a light green tint but as the hardener ages it becomes a deep red color. Since I’ve had this epoxy for a few years, all of my fiberglass parts are dark red when they cure. Adding some flox or micro turns the epoxy a pink color. The final picture shows the effect of a coat of micro added to the first coat of straight epoxy. Everything will eventually be filled, sanded and primed, so none of it will be visible, but it does make for an interesting look. Things that make you say “hmmm”…
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Completed ramp extensions

Completed ramp extensions

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Ramps fitted in place, note the contrast of colors between the ramps and extenstions

Ramps fitted in place, note the contrast of colors between the ramps and extenstions

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Everything coated with filler epoxy

Everything coated with filler epoxy

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