For many of the flat pieces, I
draw them up on AutoCAD, then print on the plotter I have access to.
Cut out the diagram, then, use double stick tape to affix it to the foam or
fiberglass or plywood that is used to start the part. Once the piece
is cut to size, sometimes still with the paper attached. Once the step
is reached where the side with the paper on needs to be cleaned or epoxied
or whatever, remove the paper and double-sided tape.
I made a couple of plywood
pieces the right size to use in clamping the duct together when it was
floxed.
I made my transition piece
plugs out of some spare urethane foam.
Here's the transition piece,
ready to be floxed into the aft heat duct. Also shown is the aft heat
duct with the aluminum tube and UNI layers that cover it installed.
Doing the outside layups on the
aft heat duct after it was assembled. I used some tape over the peel
ply to get the glass to stay put in front of and behind the aluminum tube.
I used the
Fein sander and some smaller cutoff
blades to cut the hole for the transition piece in the aft heat duct.
Here is the transition piece
being floxed to the aft heat duct.
The aft seat heat duct
installed in the fuselage with its BID tapes installed and peel plied.
I used some weights and wood blocks to keep it firmly in place and pressed
evenly to the bottom of the fuselage.
I taped a small section and
sanded inside it to ready the fuselage for the center seat belt attachment
layups.
When I do layups like this one,
I usually mark out a measured section on a piece of wax paper, then make the
layup up there and transfer it to wherever it needs to be installed after
wetting out the glass and squeegeeing.
Here's the aft center seat belt
attachment after install and peel plying.
Here's the forward center seat
belt attachment after install and peel plying.
