April 2011 – Bulkheads

The Long-EZ N916WP project officially begins on 24 April 2011!

The first chapter in the plans for actual aircraft component construction is Chapter 4, which covers the building of all the bulkheads that will make up the structural cross-sections of the fuselage.  Below is the first bulkhead to be constructed: the front (Pilot’s) seat back.

Chapter 4 — Step 1 of 4: Front Seat Bulkhead 

Front seat foam cut & shaped

Angling front seat back edge

Micro'ing front seat back bulkhead

Micro applied & spread

Front seat back glassed & peel plied

Glassed side #1 of front & rear seat bulkheads

 

Chapter 4 — Step 2 of 4: Rear Seat Bulkhead

25 April 2011 – The cured first sides of the front seat and rear seat bulkheads.  →

 

26 April 2011 – The work continues on the front & rear seat bulkheads.  ↓

#1 – A shot of the front seat bulkhead, glass completed on both sides.

#2 – Start of the foam prep on the backside of the rear seat bulkhead.

Front Seatback Bulkhead

Rear side of Back Seat Bulkhead

Below is the front side of the rear seat bulkhead.  It doesn’t look like a very nice glass lay-up on the front because it wasn’t!  I started out trying to save as much glass as I could, so I was piecing together remnants to save glass.  Boy, did I ever grow out of that in quick order!

Front side of Back Seat Bulkhead

•••

27 April 2011 – I shaped the rear side of the back seat bulkhead, and then vacuum bagged the fiberglass layup on the back side of the rear seat bulkhead, which was the second and final layup on the rear seat bulkhead.  The vacuum bagging worked really well.  The only down side is that with the hole in the middle of the seatback, it caused the plastic to wrinkle and that transfers some to the layup and leaves some epoxy ridges that have to be sanded down later.  Again, I was very happy with the outcome.

Prepping foam shape on rear side of back seat

Rough stage of foam contouring on rear seat

Vacuum bagging rear seat final glass layup

Spots excess epoxy being sucked out of layup

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28 April 2011 – Here’s a shot of the rear seat bulkhead after the vacuum bagging materials were pulled off.  I understand there is wax paper in the vicinity, and that I will burn in hell for using it, but honestly that’s what we were taught in our EAA composites course.  After being soundly thrashed by a few seasoned Canardians, I stopped the heinous practice of using wax paper!

A shot of the two finished seat bulkheads: front & rear.

•••

Chapter 4 — Step 3 of 4 

30 April 2011 – I only have this one pic of glassing the instrument panel bulkhead.  As you can see, I vacuum-bagged the instrument panel.  Vacuum bagging really does suck out all the extra epoxy and produces a much lighter part.

IMG_4372

 

Recent Posts

Project Update

Hi Folks,

I am slowly plugging along on the bottom of the plane, with it inverted as it has been for months now.  In my estimation I’m happy to report that I’m moving into the final phase of tasks to finish up the bottom of the plane that will allow me to flip the plane back upright and continue my quest to get it finished.

All the bottom surfaces of the plane are in primer, and I will start painting most of those surfaces soon.  I am also on the verge of doing the micro finish, primer and paint on the bottom components of the plane: bottom cowling, RAM air scoop/hell hole cover, landing brake, nose gear doors, nose gear strut fairing and main landing gear legs/fairings.  

The main gear leg-to-fuselage interface fairings major glassing is complete, and I’ll be permanently mounting them to the gear legs soon.

In addition, I have some ancillary tasks to complete on the nose gear actuator and main gear wheels/brakes/axles.  Once the finishing/painting tasks are completed and these ancillary tasks done, it will be time to flip the bird back upright.

I expect this bird to be inverted for another week or two before it gets flipped back upright to close out the strakes with the top skin install.

After the top strakes it will be on to the winglet/rudder install (Chapter 20).  Then engine and top cowling install, topside finish and prime/paint.

 

  1. Shop cleanup continues Leave a reply
  2. Chapter 24 – Massive shop cleanup Leave a reply
  3. Chapter 24/25 – RAM scoop final steps Leave a reply
  4. Chapter 25 – Bottom cowl epoxy wipe Leave a reply
  5. Chapter 24 – Gear fairing final tweaks Leave a reply
  6. Chapter 24/25 – Need more primer! Leave a reply
  7. Chapter 24/25 – Gear fairings ready! Leave a reply
  8. Chapter 24 – Gear fairing final glass Leave a reply
  9. Chapter 25 – Bottom cowl finish #2 Leave a reply