Title: Top windshield fairing
WIth the help of my friend Jim, we applied the top windshield fairing today: 1. Mixed up 300 g of clear resin and poured it on the previously-stacked layers of alternating fiberglass and carbon fiber pieces. I put the top sheet of plastic on it and began spreading the resin across the layup. As I suspected, the resin took a while (and some encouragement) to make it all the way through all five layers. I used pressure from a plastic spreader and, most notably, the side of a spray can pressed and rolled across the layup. I even had to add some resin. 2. Eventually, the layup was completely saturated, so I squeegeed out the extra resin, placed the cutting template on top of the plastic sheet, and used a rotary cutter to trace the pattern. I had to press quite a lot, but I was able to cleanly cut all five layers, plus the two sheets of plastic, in one pass. 3. We left the layup on the table for a few minutes and used some of the remaining resin to wet the previous layer of fiberglass on the airplane. 4. Finally, we flipped the 5-layer layup, removed the (now) top layer of plastic, and carried it to the airplane, where we laid it in place. We made some adjustments to get it in generally the right location, then peeled off the remaining layer of plastic. 5. I spent about ten minutes stippling and gently pushing it into position, with the forward edge of the layup about 1/16" aft of the edge of the previous base layer. This should leave me with a slightly easier filling & sanding job on that edge after it cures (although there will still be a lot!) 6. Applied peel ply to the entire layup.


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