Builders Update
Upper Baggage Area Fiberglass Floor Panel
Control Stick Grip - Part 2
Bonus Photo
I'm incorporating an upper baggage area aft of the traditional baggage area.
I considered what type of floor to install, including a fabric sling, netting, plywood,
and I settled on trying to fabricate a composite panel. Here's my process:
First, a look at the finished panel setting in place.
Other than repairing a smashed fiberglass Case tractor grill after a
kid (not it) drove the tractor through a fence on the farm, this is my
first attempt at making a fiberglass panel.
I started with a flat work surface (counter top material), covered with
plastic sheet (big garbage bag).
The panel will consist of a 1/4" thick foam core, with a sheet of fiberglass
epoxied to each surface.
Foam used: 1/4' Divinycell Foam PVC - supplier is Aircraft Spruce
Fiberglass Cloth
Epoxy Resin and Hardener
I cut the foam to approximate shape, laid fiberglass cloth neatly over it.
Cut to fit.
Mixed up resin and hardener. Equal pumps from each can.
Mixed in a plastic cheese container.
Followed directions.
Spread the resin mixture onto the surface using a wide plastic
putty knife. Gentle movements at a 45 degree angle.
Enough pressure to embed the resin into the cloth without
leaving puddles or excess.
Trim the edges while the cloth is gummy and
walk away to let dry.
Apply cloth using same process on opposite side.
Make a paper template to cut the panel to shape.
I drew lines on the panel.
I clamped an aluminum straight edge onto the panel
to be used a fence to follow during cutting. Used a band saw
to cut the panel straight on all four sides.
Added Piper Channel in the baggage floor area to ensure
the panel would not sag. If something were to fall through
or past the panel, the item would have direct contact with the
control cables. I placed these little stiffeners about 9 or so
inches apart. I was not confident that the panel would land on top
of the longerons enough for proper support, so the little cross
members were added.
Here's the panel in place. I will seal the edges using
epoxy and Mico Ballons at a later time, and I will plan
to post that process.
I really happy with the results. The panel is firm, flat, and
it looks appropriate.
Control Stick Grip - Part 2
One of my recent posts included the process to
make a leather control stick grip. I supplemented the
grip with a wood knob. My push to talk button is on
the side of the knob (see previous post), so I will not
have a button on top.
Here I used a piece of maple wood for the knob. I cut it to
round shape on a band saw, and stared sanding on a bench top
belt sander, then by hand to make it smooth like glass.
I cut and glued a wood insert on the bottom of the knob
to fit snuggly into the steel tube (stick).
I like it.
Bonus Photo - Wisconsin from the Air
A recent photo I took of a Wisconsin cranberry farm,
located in north central Wisconsin.
Wisconsin is the leading producer of cranberries, growing
about 60% of the nations crop (says wiscran dot org).
Thank you for looking,
John