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Sunday, October 1, 2017

3.5 hrs on the rudder top (finally getting to this...) and firewall.

Pilot hole for the wire to pass though.

Drilled out to 10mm and grommet inserted.

Lining up the tip to drill out the holes.

The rear sticks out but I'll cut that off later.

One hole done on each side and clecos inserted.  I work out from there while I hold it in position.

All done.

In case you don't think you need to clean it out after drilling composite...

Short piece of 4-wire cable inserted.

Ready to go!

All riveted.  Note the gap in the front.  I'll fix that with epoxy filler.

We'll cut that off and file it down.

Nice!

One pump of the resin, one pump of the hardener.  Mix that thoroughly and then start adding in the filler (wear a mask) until it's sufficiently thick.

That looks thick enough.  It takes more filler than you'd think to get it to this point.

Pile it on until it's beyond the outline you'll file/sand it down to.  We'll let that dry overnight and see if it's ready to contour.

Time to soundproof/insulate the firewall.  The place where the regulator goes is marked off.

Fitting the first section of soundproofing.  I measure and cut it incrementally to get it to the right size and outline.

Marking off where it will be trimmed on the outside edge.

Nice!

Did the other side and top section and it's done!!

Other side view.

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