Title: Top windshield fairing
Began building the top windshield fairing: 1. Using my previously-cut paper template, I cut the final fiberglass and carbon fiber pieces. I made them about 3/4" oversize on each edge so I can precisely trim them later. 2. Like I did with the bottom windshield fairing, I also cut another piece of fiberglass that I am going to lay down first, to act as a neat, precise edge along the windshield glass. 3. Made a 5-layer sandwich of alternating fiberglass and carbon fiber pieces, stacking them as carefully as I could. I put these aside for later. 4. Sanded and cleaned up the "ramps" in front of the canopy skirt. 5. Cleaned the bonding areas of the windshield and fuselage with 99% isopropyl alcohol. 6. Laid down packing tape everywhere I didn't want resin to get. 7. Laid down Teflon tape where the fairing will go over top of the canopy. (I later removed this and used aluminum tape, because I didn't entirely like the Teflon stuff.) I tried to make the tape fill the gap between the windshield and the canopy. 8. Applied a thick coat of mold-release wax over the aluminum tape. Used a fine brush to get it up to the forward edge of the tape, but not on the windshield. 9. Mixed resin and black dye. Between two layers of plastic, I laid up a one-layer pre-preg sandwich of fiberglass and resin, trimmed it to its final size using the template, then applied this piece to the windshield, over top of the canopy. It fit very nicely, and after some gentle pushing with a gloved finger and some stippling with a small chip brush, I think it ended up looking pretty good. 10. Added some small, curved pieces of fiberglass at the bottom aft edge of the windshield to make the radius there, then stippled them into place with more black-dyed resin. 11. Applied peel-ply over everything, and stippled it down. Tomorrow, I will add the 5-layer main layup on top of this first one.


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