Title: Windshield bonding / fairing base
Time to bond the bottom edge of the windshield to the top skin. Unlike most of the rest of the composite projects on this airplane, I am using Aeropoxy PR2032/PH3660 resin/hardener instead of the West Systems products, for two reasons: The Aeropoxy is slightly stronger, and it doesn't begin losing its strength in very hot conditions (conditions that might be found in, say, a windshield fairing sitting in the hot sun at a summer fly-in) as quickly as West Systems stuff. It also doesn't exotherm (get hot and begin curing early) as easily as West Systems, when mixed in large quantities. 1. I got all my supplies organized, made a cheat sheet for Aeropoxy mixing ratios, clamped the sides of the windshield to keep it motionless and tight, and wiped down all the bonding surfaces to makes sure they were clean. 2. First, I decided to mix 100 g of resin with 27 g of hardener, just to see how much quantity I'd need for the whole job. This turned out to be just the right amount. 3. I began mixing in flox, getting the mixture pretty thick, then I added micro and some cabosil to get it even thicker and give it the sandability and anti-sag properties I wanted. Then I mixed in a measured quantity of black dye, using a small measuring syringe. The overall mixture was like very thick peanut butter when I was done. 4. I spread the mixture along the bottom of the windshield, using a curved-end plastic mixing stick from West Systems to force it into the seam and also make a curved fillet. Here and there, I had to add a bit more of the mixture to ensure a good, even coverage. I scraped off the excess with my scraper and some paper towels. 5. On the left and right sides, I laid down some more flox and formed it into a ramp that will hopefully smooth the fiberglass transition over the canopy skirt. 6. Over the next couple of hours, as the resin began to set, I used my scraper (and later, a gloved finger) to put the final touches on the fillet shape and knock down the larger imperfections. I hope this will make the sanding job easier tomorrow. 7. While the fillet was curing, I decided to cut the fiberglass strips that will be bonded along the bottom of the windshield. Using a straight section of aluminum angle, I marked and cut seven 56" strips of BID cloth, with widths of 1/2", 3/4", 1", 1-1/4", 1-1/2", 1-3/4", and 2".


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