Finish Kit

Canopy Fairing ( 3 hrs )

Completed feathering leading edge, Step 9, Sect 38-31.  Then cleaned w/ alcohol, applied tape leading and trailing edges.  Applied smooth top coat epoxy (no filler), then removed tape prior curing.

Finish Kit

Sanding Canopy Fairing ( 5 hrs )

And more sanding !  Finally able to remove FWD vinyl tape  - and started feathering leading edge of Fairing.  Mixed epoxy and micro-balloons for "touch up" filling a few remaining low spots.   Looking good, but seems time consuming...and more sanding to go.

Forward edge vinyl tape removed.   Feathering leading edge.

added more filler.   

Finish Kit

Canopy Fairing ( 3 hrs )

More sanding !   Difficult to determine if a layer of resin over vinyl tape, or sanding of tape.   But steady progress.  Applied mix of epoxy & micro-balloons to fill low spots and some air bubbles (ref Sect 38-31 Step 6 and Vans video 38-04).   I first applied a fresh layer of masking tape along Fwd and Aft edges,  so I would NOT have another layer of thin epoxy on the tape to sand off -  then removed when epoxy started to cure.

 

filling low areas with epoxy w/ micro-balloons

Finish Kit

Sanding Canopy Fairing ( 4 hrs )

Started rough sanding Canopy Fairing per Sect 38-31, Steps 1-4 (also Van's video 38-04).   Created 6" sanding block in Step 1 with the 4" radius matching template.   Using 40 and 60 grit.   High areas and general shaping went quickly, but takes a lot of sanding to carefully remove excess epoxy over forward tape and along aft tape edge along Canopy.  Difficult to determine if sanding epoxy or black vinyl tape underneath - so frequently inspections are necessary.

Peel ply removed. 

rough sawn from laminated 2x4's

belt sander quickly finishes.  

After initial rough sanding.   Matching template

another hour and slow progress 

Finish Kit

Canopy Fairing Fiberglass  ( 5 hrs )

Whew !   Big day doing Sect 38-29 & -30 Steps 10-22 and 1-13.  Needed greater than 4 hrs essentially non-stop doing the fiberglass for the Canopy Fairing (Van's video #3 is super helpful).  The black dye in first resin batch provides opaque layer from inside Canopy just above glareshield.  These were "sandwiched" between layers of static cling to aid final trimming to size,  and especially to hold their shape as transferred from table to Canopy  - worked very well !   Used almost all of the pre-cut strips (various widths) to match the  4" radius template.  Final step was adding the Peel Ply (green nylon material), which will be removed once cured.

used template to insure Ply A's were shaped correctly

infused black dyed resin, then added top layer of static cling

ready to use rotary cutter around templates

top layer peeled off, ready to place on Canopy

adding Ply B, and small filler piece in corner
(per video instructions, this area typically needs some extra)
Ready to add resin.

Play Bs and first narrow strip...ready for resin

Ply C added to B & A...progressively smaller.  
Ready to add resin

shows layers of narrow and wider strips to create 4" radius

Peel Play  ( green nylon material)

Finish Kit

More cutting fiberglass strips ( 2 hrs )

Finished rotary cutting fiberglass using templates for Ply A, B, C, & D, plus Peel Plys for A & D.  Original blade dulled quickly, so went to Wallyworld for replacement - got a Fiskars blade pack and new handle.   Works better, and seems to be lasting longer.

ready to fiberglass next

Using a cutting board helped cutting,
and reduced blade dulling.

Finish Kit

Cutting Fiberglass ( 2 hrs )

Revised forward vinyl tape to accommodate fiberglass template Ply A using xacto knife and great caution !  Then cut 6 pieces of fiberglass at various widths and lengths per list in Step 1, Sect 38-29.  Rotary cutter works really well.

shiny area shows revised line to accommodate Ply A template

other side matching additional area (shiny zone)

after sanding.  Now matches Vans video,
but not clear why original template used
Oct 24 didn't create this exactly

several strips cut to length and width.