Project: BuckRV-8   -  
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Builder Name:Buck Wyndham   -  
Project:   Vans - RV-8   -   VIEW REPORTS
Total Hours:3914.15
Start/Last Date:Jan 08, 2002 - No Finish Date
Engine:AeroSport Power IO-375-M1S
Propeller:Whirlwind 330-3B/72H-73 3-blade CS
Panel:G3X, G5, GTN650, GTR20, GTX45R, GMA245, GMC507
 
Friendly URL: https://eaabuilderslog.org?s=BuckRV-8

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Jan 06, 2024     Top windshield fairing - (6.8 hours)       Category: Windshield
1. My friend Jim came over and helped me separate the canopy from the newly-installed windshield fairing. This was a job I'd heard could be troublesome, but we got the canopy open in less than 15 minutes (if you don't count me forgetting to open the canopy latch before we tried to open it!) We mostly used plastic hotel room keys and a small plastic spatula to work the canopy loose.
2. Began sanding the edge of the fairing where it meets the windshield. I can tell this will be a longer process than it was at the bottom of the windshield, thanks to the six layers of fiberglass/carbon fiber I have to bevel. But I made some pretty good progress before my arms started getting tired.
3. For a break, I decided to cut off the excess lip at the aft edge. I made an edge marking tool out of two small strips of aluminum, a couple of cleco clamps, and a Sharpie, marking a line exactly 1" aft of the edge of the windshield. I figured this would give me a plenty of extra material so I could block-sand it to the proper location later. I used a Dremel with a metal-cutting disc to make the cut. (I also learned that the metal-cutting disc is much, much better at cutting carbon-fiber layups than a plastic-cutting disc).
4. Marked the final desired trim line with masking tape, using the forward canopy support bar as a reference. (I wanted the lip to just barely cover the canopy rivets.)
5. Block-sanded the cut to the desired shape using a 50/120 grit PermaGrit block.
6. Worked on getting the sides of the canopy skirt to reliably fit under the lower sides of the fairing (the "pocket"). I finally got it working pretty well, but I think there's still room for improvement, especially on the right side.


 


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