There is a considerable gap, perhaps 1.5 inches, between the bottom of the windshield and the boot cowl just in front of the post. I toyed with the idea of using modelling clay to fill that in, but that is a tedius process, and basically messy. I ended up using some .005 stainless steel which I'd bought at the Kelley AFB surplus store over a decade ago, which I trimmed fill in the gaps, both aft at the post and also along the front of the windshield. These strips were held in place with electrical tape. I used some cloth to get the overall contour for a template, so hopefully, the actual fiberglass application would more readily fit. I ended up using 6 layers of medium weight fiberglass, which was testing the pot life of the epoxy. After curing, I then marked out the desired trim lines using electrical and masking tape, using a 1.5 inch upper dimension and a 1 inch lower dimension.
|