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  #1  
Old 03-24-2016, 10:33 AM
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Paddy Paddy is offline
 
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Default 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?
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  #2  
Old 03-24-2016, 10:41 AM
rocketman1988 rocketman1988 is offline
 
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Default There is a better way...

http://www.mlblueskunk.com/Windscreen_Fairings.html
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  #3  
Old 03-24-2016, 11:03 AM
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nah, skipping the fiberglass altogether would be cheating . I'm thinking maybe a flexible sanding form like a pool noodle or something might be worth a try...
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  #4  
Old 03-24-2016, 11:08 AM
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RV3bpilot RV3bpilot is offline
 
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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.
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  #5  
Old 03-24-2016, 11:55 AM
rocketman1988 rocketman1988 is offline
 
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Default AAARRRGGGHHHHH!

After the torture imposed by the awful glass work that is the cabin top, I think the aluminum fairing is looking really good...
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Bob
Aerospace Engineer '88

RV-10
Structure - 90% Done
Cabin Top - Aaarrghhh...
EFII System 32 - Done
297 HP Barrett Hung
ShowPlanes Cowl with Skybolts Fitted - Beautiful
Wiring...

Dues+ Paid 2019,...Thanks DR+
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  #6  
Old 03-24-2016, 12:06 PM
crabandy crabandy is offline
 
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Location: Ottawa, Ks
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Default

Quote:
Originally Posted by Paddy View Post
nah, skipping the fiberglass altogether would be cheating . 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.
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  #7  
Old 03-24-2016, 12:07 PM
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9GT 9GT is offline
 
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Fill and sand,,,fill and sand,,,,fill and sand,,,,,. You will eventually get there and be very happy with your results.
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  #8  
Old 03-24-2016, 12:27 PM
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Ok, sounds like persistence is the answer! Thanks to all for the input.
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  #9  
Old 03-24-2016, 12:33 PM
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bret bret is offline
 
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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 ...........
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  #10  
Old 03-24-2016, 02:14 PM
Skymanw Skymanw is offline
 
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Location: Nolensville, TN
Posts: 34
Default 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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