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-   -   Windshield Fairing (https://vansairforce.net/community/showthread.php?t=136052)

Paddy 03-24-2016 10:33 AM

Windshield Fairing
 
I'm in the process of filling and block sanding the cabin top after fitting the windows. One area that seems a bit more challenging is getting a smooth, consistent surface on the built up fiberglass fairing between the windshield bottom and fuselage. I managed to get a nice 7" radius all around with the layers of glass, but after sanding out a top layer of micro, the surface is still wavy and not as smooth as some of the finished 10's I've seen. I've been using a variety of PVC pipe sections as sanding blocks, up to 6" in diameter, but still struggling. Is it just my technique or is there a better way?

rocketman1988 03-24-2016 10:41 AM

There is a better way...
 
http://www.mlblueskunk.com/Windscreen_Fairings.html

Paddy 03-24-2016 11:03 AM

nah, skipping the fiberglass altogether would be cheating :p. I'm thinking maybe a flexible sanding form like a pool noodle or something might be worth a try...

RV3bpilot 03-24-2016 11:08 AM

Nothing fits better than a fiberglass faring that is molded to fit the fuselage. Epoxy is nasty, sticky, smelly, labor intensive work but in the end it is awesome.

rocketman1988 03-24-2016 11:55 AM

AAARRRGGGHHHHH!
 
After the torture imposed by the awful glass work that is the cabin top, I think the aluminum fairing is looking really good...

crabandy 03-24-2016 12:06 PM

Quote:

Originally Posted by Paddy (Post 1064831)
nah, skipping the fiberglass altogether would be cheating :p. I'm thinking maybe a flexible sanding form like a pool noodle or something might be worth a try...

Paddy, hello again!

I'm definitely no expert and I didn't do the front fairing out of glass, but I did use a pool noodle (actually foam protectors from the kids trampoline) on the curvy sports of my empennage fairing. The firmest material yet flexible enough to form to the shape of whatever shape your sanding. I've also used pipe insulation from the hardware stores for several smaller diameters than a pool noodle. I also have a set of "DuraBlocks" with a round block that I like.

More novice advice, don't sand with the curve.....hard to explain but picture a snowboarder in a half pipe cutting the curve on a 45 so to speak. Then sand on a 45 the other direction like a snowboarder in a half pipe going uphill. The curve should have sanding crosshatch like a freshly honed cylinder.

9GT 03-24-2016 12:07 PM

Fill and sand,,,fill and sand,,,,fill and sand,,,,,. You will eventually get there and be very happy with your results. :)

Paddy 03-24-2016 12:27 PM

Ok, sounds like persistence is the answer! Thanks to all for the input.

bret 03-24-2016 12:33 PM

interesting subject, I just posted a pic of mine in the fiberglass section, the criss cross half pipe method worked for me with a 12" sanding block with the soft round top in the curve. spent one month sanding glassing sanding glassing sanding ...........

Skymanw 03-24-2016 02:14 PM

RE:Windshield Fairing
 
I personally like the looks of the aluminum windshield fairing but do not see very many used. I think it gives a nice looking separation of windshied from fuselage and would offer a good place for paint scheme separation as well. Just curious to any downsides anyone might have....?


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