Making a Custom Gap Seal Part 2




After trimming the front and sides, place the gap seal back on the airframe and secure it in position. Center the wing template leading edge tube on the front rony bracket bolt and mark the position of the front edge of the tube on the gap seal. Then the pieces to a flat surface and use a straightedge to transfer the plane of the wing onto the curving surface of the gap seal. Be sure to keep the straightedge perpendicular to and flat on the surface of the wing template. Also, I realized later, I should have put a piece of 1/2" stock under the wing template at this point since the wing sits on top of the 1/2" door frame tube. No harm was done, since raising the wing template means you trim more material from the gap seal. I didn't wing up with a big gap to fill as a result of this oversight. I didn't attempt a final fit at this point though, just got in the ballpark.







Lots has happened since the previous photo. The mounting pad for the com antenna was made by attaching vinyl tube to the gap seal with hot melt adhesive to form a teardrop shaped dam. This was filled with epoxy thickened somewhat with microballoons and allowed to cure on a level surface. The tubing was then peeled off and the pad sanded smooth and level. The piece was then epoxy-primed which reveals all the flaws, bubbles, pinholes, and surface irregularities. This were intially filled with more epoxy thickened to trowling consistancy and sanded. Repeat fill, sand, prime till the major defects are filled and smoothed out. Final surface fairing of the small remaining imperfections is done with glazing compound (auto parts store) but the drill's the same - fill, sand, prime, fill, sand, prime, till you're happy or disgusted. Then paint. This photo shows the first application of glazing compound.




Here the compound has been sanded. At this point the defects you're filling should be so small that you actually sand away most of the compound each time you sand. You can wet sand and the wet surface will tell you how smooth and fair the surface is that you're getting. Nevertheless, when you prime it and light the piece from the side, you'll likely see still more goobers you want to fill. At this point, it's between you and your God....







Final priming applied. I've had enough. It ain't a Glasair after all.....







Back To The Index