Chapter 25 – Finishing Headrest

Chapter 25 – Finishing Headrest & Rollover Assembly

24 October 2015 — Although it’s a small piece of the headrest, I figured I would account for the GPS antenna puck cover since I was working on it.  Here’s a couple shots of the micro finishing & cheese grating of the GPS antenna cover that will go on the top of the headrest (along with the ice shields that will cover the elevator weight slots in the canard).

Cheese grating vs not cheese grating:

Cheese grating vs no cheese grating

And then when all are cheese grated:

Cheese grating wins!!

Next, I’ll final sand all these parts and start in on getting 3-5 epoxy wipe layers on this stuff.


4 November 2015 — Today I was able to carve out a little time to work on the rollover assembly.  I needed to sand down the base of the rollover on each side to clean up the irregular surfaces & shoot it with primer again.

I sanded round #1 using 100 grit paper on each side, then did a final round #2 sanding with 220 grit paper.

sanding rollover base

sanding rollover base

I then cleaned up the freshly sanded surfaces with Simple Green, took the rollover assembly outside and shot the sanded areas with 3 coats of the same Rustoleum gloss black primer that I used previously.

3 coats of gloss black primer

After hitting the rollover assembly with a few coats of primer, I decided to test out my boat paint on the headrest GPS antenna puck cover (which has clearly had pure epoxy and primer finish applied to it since my last post above).

Painting GPS antenna cover

I duct taped the antenna cover to the top of a paint spray can and then brushed & tipped on the first coat of white boat paint.  This will be the first of a few test applications I use to see if I’m going to move forward with using boat paint, or at least this brand of boat paint.

Painted GPS antenna cover


5 November 2015 — Tonight I sanded down the first coat of final top coat paint on the headrest GPS antenna puck cover, and then sanded down and added the first coat of final white paint to the elevator outboard weight ice shields.

Now, to be honest I haven’t been blown away with the performance of this boat paint.  I don’t have negative feelings towards it either, but the jury is still out.  I may need to look at a better way of applying it, because on these parts I just used a cheap paint brush.  Thus, we shall see . . .

Painting a boat!


8 November 2015 — I happen to really note the color of the boat paint on the headrest GPS antenna cover and the ice shields.  It’s not a bright white, as the primer is not, so I’ll be calling Jamestown Distributors this week to figure out the way ahead on that.  I want the white on my bird to as white as possible… not the 1970’s dull off-white stuff.  So I’ll be evaluating the paint as I move forward.


10 November 2015 — I broke out the new paint to try it out.  As I said before as I was looking at the actual color of the white boat paint I had ordered before, in contrast with the white label on the gallon can and a standard white piece of paper, it clearly looked off white.  To compare and contrast the new paint I sanded down half of the headrest GPS antenna cover with 220 grit paper, and then painted it with the new paint.  I have to say that A) the new boat paint went on much easier and laid down much better than the old boat paint, and B) the new paint seems to have more of a “blue” hue vs a “yellow” hue, as you can see below.

New paint


29 April 2017 —  Today I sanded down the GPS antenna cover that will sit atop the pilot head rest.  It too has presented a fair number of challenges.  I’m hoping over the next week to get these darn things knocked out!

I then sanded & primed the the GPS antenna cover.


10 May 2017 — Today I spent a little bit sanding down the GPS antenna cover, and it needed a few dabs of Metal Glaze for some blemish cleanup.  In addition, you just might be surprised how intricate the sanding job is on this thing, just to get what is seemingly a fairly simple & basic shape.

Here’s the other side that I also hit at the lower edge with some Metal Glaze.

And here’s the GPS antenna cover with 3 more coats of primer, which it will need to help finalize its shape.  After I give it a good wash, barring any more shaping requirements, I’ll hit it with a couple of coats of dull off-white primer as the final coat & color.


11 May 2017 — Today, my last task of the evening was to wet sand & Simple Green wash the GPS antenna cover.

After I prepped it for more paint, I hit with 3 coats of white primer/paint to cure overnight. This antenna cover will not be a gloss color, but rather either semi-gloss or even flat.


14 May 2017 — Tonight, my last official build act for the evening was wet sanding the Garmin GNS480 GPS antenna cover.  I then hit it with 3 good coats of matt clear coating (yes, crappy pic).

With that, I closed up shop for the evening and left the lovely paint fumes to themselves.


Back to Top


Recent Posts

Project Update

Hey Guys,

Well, the weather is slowly warming up (above freezing anyway)… and here soon I should be back in the shop to work out the finer details of making everything fit inside the cockpit, and then get onto much bigger build tasks.  I still see a very real light at the end of the tunnel for all my in-cockpit install shenanigans, and expect to be done with those in about a 2-week total time span once I get started on them again. 

I’m still working on the electrical system taskers and chipping away at them all while making decent progress.  

The past few days –after finishing the major engine build & bringing it home– I have been finally able to do some research with engine in hand to discover the more esoteric (read: “oft forgotten”) bits ‘n pieces that may not be obvious requirements when simply planning/purchasing major components for the engine build. One example of many are the nuts and bolt required to mount the starter… which are not included with the starter, nor the engine.  So, with the weather still cold (dipping into the 30’s at night), I carved out 2-3 days to figure out what engine stuff is required, which version to buy, and where to purchase it from.

Still, seriously … having finished the vast majority of the Electrical System; Instrument panel design, install & wiring; and now the Engine, I can say with very high confidence that the big build stuff is coming up  SOON (including the wheel pants…) AFTER the weather warms up a bit.



  1. Chapter 14 – Lower extrusions installed Leave a reply
  2. Chapter 14/23 – Baffling Extrusions Leave a reply
  3. Chapter 14 – Lower engine extrusions Leave a reply
  4. Chapter 14/22/23 – Engine mount prep Leave a reply
  5. Chapter 23 – Engine Preservation Leave a reply
  6. Chapter 3/22/23 – Work bench finished Leave a reply
  7. Chapter 22/23 – Engine Parts? Check! Leave a reply
  8. Chapter 22/23 – Engine Inspection Leave a reply
  9. Chapter 22/23 – Electrical Workbench Leave a reply