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Step 1 CARVING THE FOAM PIECES |
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Ok, this is a lousy picture but
I can't resist showing it. I did
CAD drawings for Chapter 8 parts,
then, used double- stick tape to fix the paper to the foam. Rough cut
the parts to shape on the band saw, then, sand to final shape and do the layups on the non-papered side. |
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Here are the two shoulder rest
pieces, cut to size and with the plywood inserts installed. |
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Since I was changing the order
slightly on how I would assemble the shoulder brace, I needed to make the
fiberglass buildups earlier than specified. Here's the 5" by 5" layup,
with a piece of wax paper underneath with 1.25" x 1.25" squares marked on
it. I do this a lot when making a piece to a given size, the marker,
once the layup is wet out, shows through from the was paper below. |
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Oops I did it again.
While sanding the buildups smooth with the surface of the PVC foam, I broke
this piece in half. Probably could have microed it back together, but,
I'm such a perfectionist I made another one. Besides, I didn't like
how the buildups turned out. |
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Here's the second, do-over
piece with the buildups curing in place. |
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I used the piece of wood to
evenly distribute the weight so the epoxy didn't leak under the piece while
the buildups cured. |
| There are no more
pictures to show for this step because I am waiting to do the headrests
later. I will probably build them according to plan, but, want to make
sure I make all the mods I want to, like installed radio plugs before I
install them. Next step is Glassing the
Inside. |
