Brief Description: Enclosed HS Tips using Plexiglass & Fiberglass.
I knew that I had some plexiglass around somewhere but it took an hour to find it. It was behind my old workbench against the wall and invisible to the eye. It had been there since I moved in 6 years ago. I decided to use it to enclose the HS tips and reinforce it with fiberglass and epoxy. It would remain there permenantly. I traced the outline of the tip onto a piece of paper and then cut it out for a pattern that I traced onto the plexiglass. I cut the plexiglass with the band saw and final shaped it with the ScothBrite wheel on the grinder. I then epoxied it into the tip leaving about a 0.1" from flush to add the fiberglass and more expoy. It all came out ok after curing for 12 hours. I sanded the rough stuff off and installed the tips using the CS4-4 pop-rivets. I will use epoxy and filler later to cover the rivets and smooth after installing the HS on the airplane.
