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Bob's RV-8 Build Site
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Date:  1-25-2020
Number of Hours:  7.70
Manual Reference:  
Brief Description:  Fabricate Band Clamp / work on L & R Fairings

I started the session with going out into the shop and fabricating the band clamps. After making them I tried them on for size. The concept seems to be solid and I think they will work well I just have to go purchase some 3/8 inch thick aluminum stock to replace the 1/2 inch thick stock I am currently using. The 1/2 inch stock is a little too stiff for being a good clamp....and the thinner clamp should work well.

If you recall I am using sikaflex bonding compound to adhere my canopy and my skirts. The skirts also have numerous rivets that will rivet into the frame as well so they will be attached with both a chemical and mechanical process. The banding will hold the flange of the skirts tight against the canopy while the sika is curing.

Before any of the bonding can happen I still have lots of work on the skirts. The gap in several places on the skirt flanges on both sides need work. There are gaps between the flanges and canopy that would make the sika thickness very inconsistent....it would no doubt adhere fine but it would look horrible. Also to clamp the fairing against the canopy would work but then there would be a constant pressure of the flange trying to pull away from the canopy and I don't want the sika doing that hard a job to "keep it all together". You never know if time would eventually cause the flange to pull away.

I prepped and started laying extra layers of fiberglass on the flange where needed. The process will be to add the fiberglass where the gaps exist and then grind down the outside of the “pink” fiberglass to the new strips to get the flange to a uniform thickness. Once again, functionally I could just use it the way it is and it would work fine….but it would be ugly….so I have to spend the time. After laying up the fglass cloth I clecoed and installed both fairings to have them in place and allow the added fiberglass to conform to the fairings while in place using clear packing tape to protect the canopy.
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Band Clamps

Band Clamps

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Testing Clamps

Testing Clamps

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More fiberglass laid

More fiberglass laid

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