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1. 07:13 PM - Fitting Fairing to the Fuselage, how I do it...... (Michael Kraus)
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Subject: | Fitting Fairing to the Fuselage, how I do it...... |
Here is a better description of how I fit my fairings..... Can be used
for the gear leg to fuse, gear leg to wheel pant, or rear empennage
intersection fairing.
* Rough cut and dry fit up fairing to airplane. Drill #30 holes in
locations where screws will eventually hold fairing to fuselage. When
satisfied with the fit, draw a marker line on the fuselage around perimeter
of fairing. Remove fairing.
* Use mold release (I use the car wax stuff from Aircraft Spruce) and wipe
it all over the fuselage about 2-4=B2 or more around both sides of the line
you drew. DO NOT FORGET TO DO THIS STEP OR YOU WILL VERY UNHAPPY!!
* Scuff up inside of fairing with 36-40 grit sandpaper on all surfaces wher
e
they will come into contact with the fuselage.
* Clean fairings real good with acetone or similar to remove any
dust/dirt/residue/mold release, etc
* Work on one side of one fairing at a time (for instance, if you are
working on the upper fuselage to gear leg intersection fairing, work on the
fuselage to fairing interface first. Second time around work on the fairin
g
to gear leg interface). Lay up 2-3 layers of approximately 9 oz cloth on
the fuselage over the line drawn in step 1.
* Mix up flox and epoxy to a peanut butter consistency and apply about
1/16=B2-1/8=B2 onto the fairing surface that mates to the fuselage. This will
help fill any gaps that may be present due to poorly formed fairings.
* Mash the fairing onto the fuselage in position. Use
cleco=B9s/clamps/screws/whatever you desire to hold it in place exactly where
you want it until dry.
*
* Once dry, use compressed air to blow it free from the fuselage. Its
amazing how well the compressed air works. Just get a little spot to break
free, then blow air in the spot and the whole thing will pop off pretty
easily.
* Clean the fuselage up with a plastic scraper and acetone and clean real
well.
* Trim the fairing edge as desired to get a smooth edge.
*
* Repeat the process for the other side of the same fairing. For this
example, that would be the upper gear leg to fairing surface (or the lower
line as described above). DON=B9T FORGET THE MOLD RELEASE ON THE SURFACE YOU
DON=B9T WANT IT BONDED TOO!
*
* Once complete, fill and sand, and fill, and sand, and fill, and sand unti
l
it is smooth to your satisfaction.
For the rear empannage intersection fairing, I followed the same process,
but layed up the HS to fairing surface first, then the VS to fairing surfac
e
second.
I hope this is not too confusing. It is actually quite easy, just takes
time.....especially in the Michigan winters when even fast drying epoxy
takes 2 days to cure!
-Mike Kraus
RV-4 Flying and Sold
RV-10 Flying
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