Title: Contouring the Bottom
06/16/2004 (2 hours): I've been getting less working time lately, because I'm changing jobs and addressing my outstanding obligations has been a bit of a headache. Also, Elliott's sleep cycle has changed and has required more of my attention at night, so I'm just not getting as much Cozy time. Life goes on. I did manage to take a few hours this evening to use my new belt sander to make the 45- degree angle bevel on the lower longerons from F22 back to the landing brake. I first cut the foam down to the edge of the longeron with a coping saw, then sanded the longeron to a 1/4" wide exposure. 06/24/2004 (1.25 hours): Another short day, but I'm feeling the building-bug kicking back in, finally. Tonight I cut the bottom contour guide and started in on rounding the bottom. I'll probably have a little bit of retouching to do around F22 but I'll address that later. In the first picture below you can see the tools of the trade. I use the saw and Surform plane to do the rough shaping. The Surform also does an amazing job of cutting through the micro without making little chunks that gouge the urethane spacers. I use the brush frequently to keep the sanding area clear, and I've basically been doing the rest via good, old-fashioned hand sanding, both with the block you can see in the picture and with the 2x4 jointer sander you make for sanding the NACA scoop. 09/26/2005 (4.5 hours): For the past few days, I've put several hours into finishing the shaping of the fuselage bottom. I've repaired most of my errors at this point, and I'm working my way up to glassing the bottom. Hopefully I'll be glassing by the end of the week. It's good to get back into the project! 09/27/2005 (2 hours): Today I sanded the recess around the landing brake, and built up the duct-tape layers around it. The duct tape edges are a little ragged, but it looks OK. I also skipped the installation of the wood block for the step. I've seen and used Marc Zeitlin's retractable step, and much prefer it to the plans design. It didn't take as long as I'd thought to shape the bottom, although I may have lost track of a few hours from before the move. I think I set the estimate based on doing all of the contours at once. The plans call for the upper section contouring to be done after the first layer of glass is down on the bottom.


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