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03-24-2016, 10:33 AM
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Join Date: Jul 2008
Location: Prosper, TX
Posts: 373
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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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RV-10 N415JS
Slow build kit #40874
Homebuilt Kit Champion Oshkosh 2019
Atlantic crossings: 2
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03-24-2016, 10:41 AM
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Join Date: Jun 2010
Location: Sunman, IN
Posts: 2,189
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There is a better way...
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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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03-24-2016, 11:03 AM
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Join Date: Jul 2008
Location: Prosper, TX
Posts: 373
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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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RV-10 N415JS
Slow build kit #40874
Homebuilt Kit Champion Oshkosh 2019
Atlantic crossings: 2
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03-24-2016, 11:08 AM
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Join Date: Oct 2012
Location: New Ulm, Minnesota
Posts: 283
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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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Robin Mckee
New Ulm, MN 56073
RV3b N219BB
420 hours and counting
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03-24-2016, 11:55 AM
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Join Date: Jun 2010
Location: Sunman, IN
Posts: 2,189
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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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03-24-2016, 12:06 PM
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Join Date: Jan 2010
Location: Ottawa, Ks
Posts: 2,188
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Quote:
Originally Posted by Paddy
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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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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RV 7 400 hours and counting
19 donation done
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03-24-2016, 12:07 PM
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Join Date: Jan 2010
Location: Southern Michigan
Posts: 1,966
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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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David C.
Howell, MI
RV-10: #41686 Under Construction
RV-9A: #90949 Under Construction
RV-10: #40637 Completed/Sold 2016
Cozy MKIV:#656 Completed/Sold 2007
"Donor Exempt" but donated through Dec. 2020
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03-24-2016, 12:27 PM
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Join Date: Jul 2008
Location: Prosper, TX
Posts: 373
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Ok, sounds like persistence is the answer! Thanks to all for the input.
__________________
RV-10 N415JS
Slow build kit #40874
Homebuilt Kit Champion Oshkosh 2019
Atlantic crossings: 2
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03-24-2016, 12:33 PM
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Join Date: Feb 2010
Location: Gardnerville Nv.
Posts: 2,828
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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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7A Slider, EFII Angle 360, CS, SJ.
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03-24-2016, 02:14 PM
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Join Date: Jan 2015
Location: Nolensville, TN
Posts: 34
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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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