Message-ID: <3827819F.65249828@atlantic.net>
Date: Mon, 08 Nov 1999 21:06:23 -0500
From: "Robert J. Stia" <rnr@atlantic.net>
To: Fredmoreno@aol.com, "lancair.list@olsusa.com" <lancair.list@olsusa.com>
Subject: Re: Finishing inspection doors and covers
References: <0.9291bd5f.2557aaea@aol.com>
Mime-Version: 1.0

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Fredmoreno@aol.com wrote:

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> New topic.  I want all you finishing experts to spill your guts.
> The question: what is the best way to get that nice, narrow, uniform width
> gap around the inspection covers?

Wellllllll......Fred, as you must surely know by now, ain't nothing easy or
fast. Requires lots and lots of patience.

Here is how I did it.  Make the inspection panel shape perfect. Straight sides,
well radiused corners, etc. Wrap the edges of the panel with release tape of
some kind. (So it won't be glued down by the micro you are going to apply) Clear
thin cellophane type of packaging tape.  Fasten the panel down with it's
fasteners. (flat head screws and nut-plates normally) Make sure the height when
fastened down is faired to the surrounding area. This should not normally be a
problem if you faired the inspection plate to the opening when you put on the
mounting flange. If not, put micro on the mounting flange to build it up and
then let it dry before proceeding further. ( I had one or two that were a little
low in one or two corners that needed to be built up) Use a short straight edge
across the face of the inspection plate and its surrounding area to check this.

Now, after the inspection plate is screwed down tight and is faired level to the
surrounding area, cover the flat head mounting screw (also need to be flush with
the face of the inspection cover) with clear release tape, or simply fill the
screw head with wax or modeling clay etc. (so the micro doesn't fill the screw
slots)

Mix up some micro and just smear it into the space between the edge of the
inspection cover and the area around the cover. Mix it kind of like the
consistency of whipped cream. Let it set up a little bit until it starts to get
stiff. Take a utility knife and grind the pointed edge into a small radius. Dip
the blade into water and then run the point of the knife around the inspection
cover. If the micro sticks to the blade, dip it again.

The micro will "pile up" on each side of the blade as you "cut" your gap. Resist
the temptation to flatten or smooth it. After your "gap" is satisfactory. LEAVE
IT ALONE.

After the micro has hardened sand everything down flush.
If you used release tape extended over on to the top surface of the inspection
plate, that will sand away. You should now have a very flat even surface with a
very uniform gap.  Dig out the wax or whatever in your mounting screws, take off
the cover, clean everything up, and you should have a very nice fitting
inspection cover.

Don't know why I should be telling you guys this. Might be competion for me.

Bob Stia N96ES  (Best Composite Sun-n-Fun 1999)

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