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  #1  
Old 11-27-2011, 05:48 PM
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CharlieWaffles CharlieWaffles is offline
 
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Default Canopy Interior Fiberglass Prep Work

I am just about to be ready to prep my canopy for painting and the Aerosport Overhead console. I've done a lot of reading and research and there is some good fiberglass information but a lot of it pertains to fairings or making your own parts.

So what I am wondering is, what have other people done to prep their interior canopy? From what I can tell, here is what I need to do:

1) Corse sanding with 80 grit to knock down large bumps and shape general contour. This will be done WITHOUT a rubber block

2) Dust and wash surface

3) Epoxy and squeegee for warts, low areas and pinholes

4) Sand with rubber block and repeat epoxy as needed

5) Shoot with high build primer and sand to ensure all areas are smooth

6) Paint

Any comments or recommendations? Vans builder manual says to thin the epoxy when doing this, but everwhere else I've read doesnt mention thining it.
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  #2  
Old 11-27-2011, 06:50 PM
aerhed aerhed is offline
 
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Sounds right. You may want to attack with a DA disc on the really lumpy areas. Saves on raw fingers. Probably have to use some filler too.
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Old 11-27-2011, 07:20 PM
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I'm using a power finger sander (a 1/2" wide belt) for the initial contouring. I assume the filler you are referring to is microballon type for the low areas?

Recommendations for sandpaper grit post epoxy layer?

What high build filler would anyone recommend?
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  #4  
Old 11-27-2011, 08:12 PM
aerhed aerhed is offline
 
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You won't go wrong with micro. Even Bondo would be okay inside since its out of the weather. Post epoxy I'd try a 180 open cut and finish to like 220 before primer. If you do that and a nice smooth job to start, you will be able to minimize the primer thickness. If you're painting instead of upholstering that can minimize cracking later. Don't know what your planning up top, but if you PM me I can give you some ideas about window surrounds, antennas, etc.
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Old 11-27-2011, 08:28 PM
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I have the aerosport console and headliner. So most of the work will be the beams and edges where they show.
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  #6  
Old 11-27-2011, 08:45 PM
aerhed aerhed is offline
 
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I think that's got to be quite a bit easier. I guess then you only need to do good on the Knobby area aft of the doors and all the doorposts. I upholstered mine along with the console, so I really cheated. All I had to do was get smooth.
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Old 11-27-2011, 08:50 PM
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Is it safe to sand down those knobby corners? Surprised how bulged it is.
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Old 11-27-2011, 09:03 PM
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I installed the same console. I used a DA sander to do most of the rough sanding. It takes a long while to get it close before you can fit the overhead in. I used epoxy mixed with flox to "glue" the overhead on. I then used fairing filler/micor balloons to fill the front portion of the overhead intersection with the door. The area where the headliner comes against the console I did not use any filler since it is hidden. If you are using the Mcmaster Carr trim, now is also a good time to get the edges built up to accept the trim and to add reinforcement on the sides of the door pillars to take care of the material you removed for the seal. I used 6 0z cloth, seems about 4 layers, the followed with flox. I posted some photos of the process below. Yes, it's safe to sand them down.




















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Last edited by Bill.Peyton : 11-27-2011 at 09:06 PM.
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Old 11-27-2011, 09:17 PM
aerhed aerhed is offline
 
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Bill's nice work looks like what your going for. Especially up front there. I made my console detachable (I've got 4 antennas and some other wiring stashed up there).
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Old 11-27-2011, 10:35 PM
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Bill, I plan to use the Mcmaster seals. What did you use to determine how much to cut on the door opening? Just remove all the curve?
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