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Unread 02-19-2012, 07:37 PM   #16
Old4X
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Personally I would do an original "Body by Fisher". Fisher used to make car and truck bodies from wood. I would cut a piece of 3/4 inch plywood and line it up with my already installed bulkhead.

Then use epoxy proof foam blocks and glue to the cut top and plywood piece. Sand and carve the foam to shape, and cover with glass and resin.

The complex curves in the fiberglass will give lots of strength. Would probably imbed some sheetmetal reinforcement clips in 4 or 6 places, and cover well with glass.

This is how some of the super-slick homebuilt airplanes are made these days.

The work is mostly in the setup and measuring, the actual glassing is secondary.

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Unread 02-19-2012, 07:39 PM   #17
Old4X
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Once the rear wall is done, find a window you like, and cut an opening for it, and install it.
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Unread 02-19-2012, 08:34 PM   #18
k-bar
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Once the rear wall is done, find a window you like, and cut an opening for it, and install it.
sweet, I am def ready to do this now!!
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Unread 02-19-2012, 08:35 PM   #19
k-bar
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Oh and where can i get some epoxy proof foam blocks?
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Unread 02-19-2012, 08:42 PM   #20
Old4X
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http://www.aircraftspruce.com/

You might find it locally, but these folks definitely will have everything you could ever need.
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Unread 02-20-2012, 05:04 PM   #21
k-bar
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http://www.aircraftspruce.com/

You might find it locally, but these folks definitely will have everything you could ever need.
All the foam on that site is compatible with epoxy. I cant find any that is epoxy proof
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Unread 02-20-2012, 07:10 PM   #22
Old4X
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You will need to research the current materials, most of my work was in the late 80s. I did some fabrication at that time. Since then only repairs and touch-ups.

I used blue polystyrene, mainly because I was doing a lot of hot-wiring.

From my catalog, it appears Last-a-Foam works well also.

You will want one of their catalogs, very instructional.
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Unread 02-20-2012, 07:27 PM   #23
Old4X
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All the foam on that site is compatible with epoxy. I cant find any that is epoxy proof
Epoxy proof/ epoxy compatible, would be the same for your requirements.

Some foams have wider resistance to glues, solvents, fuels, etc, and I tended to work on different and odd projects, so I stayed with the most compatible for my uses. There may be plenty of other formulations available today that will do what you want. Plus if you hot-wire the wrong foam, it produces poisonous gas.

Epoxy is the most forgiving IIRC as to compatibility, but it is several times the cost of some other resins, so there is a trade off.
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Unread 02-20-2012, 08:11 PM   #24
k-bar
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Originally Posted by Old4X View Post
You will need to research the current materials, most of my work was in the late 80s. I did some fabrication at that time. Since then only repairs and touch-ups.

I used blue polystyrene, mainly because I was doing a lot of hot-wiring.

From my catalog, it appears Last-a-Foam works well also.

You will want one of their catalogs, very instructional.
Whom's catalog?

Thanks again for all the great info btw. You def seem to know what you are talking about.
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Unread 02-20-2012, 08:55 PM   #25
Old4X
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Whom's catalog?
Aircraft Spruce
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