by stearmoth » Tue Aug 01, 2017 12:04 am
Dear Paul,
Nice to hear from you and thank you for your comments! I am pleased to answer your questions as far as I recall. Sam is in holydays right now, but I will tell him to answer the leather coaming technics when he is back:
1. what thickness and what alloy of aluminum did you use for the cockpit cowling? --> 1/32" is used on all top of longeron cowings. It think it's T1 quality
2. did you reinforce the cockpit opening in any way? --> although the deck has been raised, we made a tubing reinforcemnt on both side of the cockpits typically as per Classic plans except whre is the door. The website should show this.
3. what did you put over the cut edge of the aluminum and how is it attached? --> It's a rel. hard polyurethane foam rim used as a sanitary insulation for water lines. It is cut lenghtwise an just put over.
4. what did you use for padding beneath the leather? --> Sam bett knows as he did it!
5. any tricks for cutting and forming the leather? Did you curve the pattern, or just form it from straight material? --> It think it's from straigth leather, but Sam better knows
6. what did you use for lacing? --> real leather lacing
7. how did you attach your headrest? I don't see any fasteners... --> the headreast is the only part, that is made from fiberglass covered 60 kg/m3 PVC foam (today we would it rather form from aluminum). The foam was shaped to follow the rear cockpit covering (this is a 2 ply 1/32" plywood lamination formed over a styrofoam block as a pattern). Then, we inserted a few plywood pieces into the foam' underside with metal inserts, marked their position on the plywood decking. Then attached a plastic over the decking as a separation device and layed fiberglass with epoxy over it and the the foam core. After cure, we shaped the headrest to it's final form with a sharp edge along the plywood decking. After that we covered the headrest with two layers of fiberglass and so on. Then comes the final sanding ....
8. anything else we should keep in mind? --> there are numerous things, just ask and we try to answer as well as we can!
Good luck! How do you come along with your project?
Kind regards
Hans & Sam, H.C#78, Switzerland
Dear Paul,
Nice to hear from you and thank you for your comments! I am pleased to answer your questions as far as I recall. Sam is in holydays right now, but I will tell him to answer the leather coaming technics when he is back:
1. what thickness and what alloy of aluminum did you use for the cockpit cowling? --> 1/32" is used on all top of longeron cowings. It think it's T1 quality
2. did you reinforce the cockpit opening in any way? --> although the deck has been raised, we made a tubing reinforcemnt on both side of the cockpits typically as per Classic plans except whre is the door. The website should show this.
3. what did you put over the cut edge of the aluminum and how is it attached? --> It's a rel. hard polyurethane foam rim used as a sanitary insulation for water lines. It is cut lenghtwise an just put over.
4. what did you use for padding beneath the leather? --> Sam bett knows as he did it!
5. any tricks for cutting and forming the leather? Did you curve the pattern, or just form it from straight material? --> It think it's from straigth leather, but Sam better knows
6. what did you use for lacing? --> real leather lacing
7. how did you attach your headrest? I don't see any fasteners... --> the headreast is the only part, that is made from fiberglass covered 60 kg/m3 PVC foam (today we would it rather form from aluminum). The foam was shaped to follow the rear cockpit covering (this is a 2 ply 1/32" plywood lamination formed over a styrofoam block as a pattern). Then, we inserted a few plywood pieces into the foam' underside with metal inserts, marked their position on the plywood decking. Then attached a plastic over the decking as a separation device and layed fiberglass with epoxy over it and the the foam core. After cure, we shaped the headrest to it's final form with a sharp edge along the plywood decking. After that we covered the headrest with two layers of fiberglass and so on. Then comes the final sanding ....
8. anything else we should keep in mind? --> there are numerous things, just ask and we try to answer as well as we can!
Good luck! How do you come along with your project?
Kind regards
Hans & Sam, H.C#78, Switzerland