Sender: <marv@lancaironline.net> (Marvin Kaye)
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Date: Mon, 30 Aug 2004 13:03:48 -0400
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Subject: Re: [LML] Finishing techniques
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From: "John Schroeder" <jschroeder@perigee.net>
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Gary -

Our fastbuild door for the ES is a carbon fiber one adapted from the IV.  
That's what they shipped us. We had to do some edge buildups around the  
frame and to match wing tips to ailerons, etc. We glue strips of  
tape-covered, thin material (like trimmings from the aileron skins) with  
hot melt glue in positions to form channels and dams. We extend them  
slightly to allow for shaping and sanding. We use a flox wi/ a little bit  
of cabosil (ACS has it). The cab is a thixotropic material that thickens &  
makes it stay in position better. It also makes it spread and shape a lot  
easier. To shape, we found that a 1/4 90 degree die grinder is the best to  
get it started befored going to sandpaper. We use a 2" "Roloc" adaptor  
with 2" 40, 80 & 120 grit disks. If you take it easy  with that piece of  
machinery, you can get very good in shaping. BTW, a squirt of acetone on  
the hot glue loosens it so that a sharp chisel can scrape it off. Very  
little residue remains that another shot of acetone and scuff of sanding  
won't take care of.

We follow the flox wi/ a thin coat of micro to fill any pinholes. The  
edges we have done really are hard. If we have to make sure that a block  
of flox will stay intact, we drill a few small holes in the edges of the  
area to be built up. They provide "pins" of flox when dry. in a couple of  
cases, we covered the flox wi/ a 1 BID and a bit of micro sanded.

John


> To add to the other questions that came up, what about corners that have  
> to
> be built up?  Notably around the door, there are areas on my ES that  
> have to
> be built up to form an outside corner.