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Marlins Web Site
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Date: 6-5-2023
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Number of Hours: 12.00
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Manual Reference: Sec 6, DWG 6
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Brief Description: Empennage Fairing Fiberglass Rebuild (Cont.)
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To install the Tinnerman Washers into all the fiberglass parts where a flush screw secures the fiberglass, is a nine-step process. First, I countersunk all the screwhead locations and installed the screws to insure they would be flush and correctly positioned. Next, I removed the screws and used a Dremel Tool with an oblong grinding head to make the countersink area bigger and deeper. The third step in the process is to use a bigger grinding head to make the divot hole even wider. The fourth step is to use a barrel-shaped grinding head to slightly inset a one-inch flange hole for the Tinnerman Washer flange. Next, I mixed up some fiberglass epoxy resin mixed with microbeads and flox and slabbed some into the holes, followed by a Tinnerman Washer. The sixth-step is to dip the screws into melted candle wax to preclude epoxy from sticking to the screw, then tighten the screw into the Tinnerman Washer and it’s corresponding nutplate. The seventh-step in the Tinnerman Washer process is to let this cure 48 hours and then sand smooth. The eighth-step is to sand the fairing to its final shape. The final step is to use a primer-filler to fill in any remaining pinholes, sand, and prime for paint. I actually had a 10th step which was to add 8 strips of fiberglass cloth to the backside of the Tinnerman Washers because this fairing was so thin, in two places I Dremeled-through the fiberglass and made a 1-inch hole where a Tinnerman Washer was supposed to go…GRRR. It’s a lot of extra work and expense to do this, but I should never have a fiberglass crack from a screw head, using Tinnerman Washers.
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Screws Countersunk into Fairing
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Left Side
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Tinnerman Washers set in Epoxy
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