HOW TO: (Screw Up) and Make a Fiberglass Fairing
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- Опубликовано: 21 май 2020
- I have a cylinder that is hitting the inside of the lower cowl. So I needed to make a blister on the cowl to give the offending cylinder some room to play.
This didn't go as planned! Watch to find out how I made the fiberglass blister.
Please help me out by smashing the thumbs-up button, leaving a comment, and SUBSCRIBING to the channel. Thank you!
#fiberglass #aviation #experimentalaircraft #customparts 
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Very much like the fact that you proceeded to rework your first attempt, to improve upon it because you weren’t satisfied with the initial outcome.
It is the learnings, insights and expertise we develop from ‘doing’ that allows us to produce better results each time around.
Bravo 👏
That's true. My neighbor is a fiberglass master and sometimes I feel like I want to take the cowl or some other part to him and say, "here...can you make this for me?" But if I did that, then my skills would never improve. Same with painting-I'm still not very good at it, but the more I do it, the better I'll get!
i find it funny how a solution to a problem can make the aircraft look better :)
Nice!
Great channel - ony just saw this video. Many years ago I was in motorsport when carbon fibre was all new, we used to do mods similar to your cowl blister & try to make it look like we hadn't screwed up and had done a rework.... next time think in reverse & make a mould with the foam - cut out your blister like you did, plus about 5-10mm all around, then work the foam to fit the outside of the cowl. With a marker pen mark the extent of the cut hole onto the foam from inside the cowl. Remove the foam & now sculpt out the blister, like when you peel out a melon with a spoon, on the bench. When you are happy, give it a quick coat of jelcoat or even paint to get rid of the worst of the foam cell roughness. Doesn't need to be absolutely perfect. While this is drying, attack the inside of the cowl by grinding/sanding away from the hole blending out about 30-50mm from almost a knife edge at the hole edge. Once the jelcoat is dry, apply mould release to the mould block then tape the foam block in place onto the cowl. Apply a liberal layer of clear jelcoat into the blister mould (doesn't need to be clear if you are going to paint the final cowl), making sure the jelcoat loads into the edges of the cowl cutout, but don't clearjel the cowl fibreglass that you have ground away - if you do too much, grind the excess off with a dremil. Now lay up a couple of layers of carbon (or glass cloth in your case) out to where you ground back the inside. This gives a strong joint of the blister to the cowl - doing it to the outside tends to give you only a small structural bond area between them. Once all dry, the inside can be given a quick touchup, and the outside just needs a quick sand & polish, and at worst if you are doing it with carbon & clear jelcoat, you might just get one or two little bubbles to fill :-) Looks a million bucks, next to no extra filler if any, and a strong bond. Another trick to check clearances - get some plastercine/modeling dough and roll beads then press lightly to have then stick on one surface - sometimes a tiny bit of hair dryer heat helps it soften if it's a cold day, then fit the component & the indentation should give you the dimension (we used the same trick on pistons to double check valve clearances!)
Looking forward to more videos :-)
Thank you for your videos! Not only are they helpful for specific task guidance, the opportunity to witness the patience and creativity required for homebuilding is a welcome opportunity to calibrate my approach to my own kit project...The journey is the destination.
Well done.
I’m building a Sport Performance Panther and I think your video is going to help me a lot in making corrections to a very poorly fitting rear tail feather faring. Thanks again for the great video.
Nice, getting really close. Can't wait to see it up in the air for more than a fraction of a second!!!
Hotel keys, they sure make for great tools. Thanks #hiltonhotels. Can't wait to see it take flight!
I have a whole bucket full of them!
Second version was very well done. Love watching and learning from you. Great work sir!
As i get closer to launching my build, I'm delving into learning all kinds of ways i can fabricate parts. Learning from Mark, here, Mike Patey for the doors, Rob Caldwell for some of the ideas he has, and so on. Thanks Mark. Appreciate the lessons.
I have done a little fiberglass fabrication and appreciate learning more from your videos! I've had the same experience as you - the second attempt always goes better than the first! To say the second fairing looks like the cowling came that way from the factory would be an insult - yours is very nice!
thanks!
Nice work Mark. I think you need one on the other side, then you could paint them to look like eyes. When you eventually take those valve covers off to fix the rub mark have them all powder coated a color to match the paint job.
Congrats on the 10,000 subs.
Good job.
👍👍 helpful. Will try to mod my motorcycle fairing
Excellent video, I’ve only worked with flat fiberglass parts, was looking forward to seeing how you were going to make the blister. I also like how you do a combination of voice over narration as well as the normal live video. Cheers
I like this channel. Congrats for the 10k subscribers.
Nice glass repair! Great practice for when you decide to build a #glasair.
congratulations on all the subscribers... I had a Kit Plane many years ago with a 584 Rotax, I had a similar issue and I realized with the engine torquing and either left or right turn, the engine would sway a bit and still touch the cowling. anyway, good luck. thanks for the update,
I was happy to see you start over with it (12:26) I saw it looking "too close" for my comfort, and I'm not even a pilot...
Looks great!! Good seein you again.
Good detailed information, thanks.
Thank You for the tip.
Nice job !
Great Video as always!
Really would like to see the complete build of the new Zenith.
congratulation on the 10k subscribers.
Another- outstanding job! Hey, did you ever think of putting another blister on the other side and making them into eyes?
Great job. I do the same as u. When I’m not happy I just redo till I’m happy. Also you could of left foam in and used acetone to melt it away after glass is formed.
Other than the crap of the bubble! You know? Weh! I thought the process could be done as such, its another thing to have somone agree and show thier work! Again, ugh! We make things work
Time to get that bird in the air!
Very soon I hope!
Hotel room key cards.. I use them too for fiberglass work! Are you an airline pilot by chance?
Pretty good! Did you make the cowel from scratch? I need to see the process. I have plans for an ultralight, and am confident I can handle all the other stuff. I'll need to build a cowel from scratch. Thanks!
👍👍👍
You are so meticulous and it shows int the quality of your plane.
Nice, work. I have a few questions about the materials used. What is the handling time and cure time for the epoxy resin used? Do you recommend epoxy with microballoons as an option to your filler paste choice? Thanks, Kurt
Great intro to making fiberglass mods!
Great work! What's the word on getting an inspector over? We need to see it in the air (and going higher than four feet this time)!
Paperwork was sent yesterday. The inspector will review it and call me next week to set up the inspection!
@@KitplaneEnthusiast Awesome!
Good Job
Do you have more “Fairing” videos like your wing filets and how they were made?
Yes just look on my channel. I've made a few videos on the way I fiberglassed some parts. I say "the way I.." because there are many different ways to make fairings!
Mark... wear gloves 🤓
Hi Mark how many layers of cloth did you use when making the windscreen faring, I’m attempting mine this weekend. Thanks
I think I used two layers on that fairing.
Not bad. I am not sure weather I would still have worked it from inside the cowl. I also think if I was to do it as you did on the outside I would have used the smaller piece of fibre glass and worked out as that might have made the steps less pronounced. Just some thoughts, what do you think?
That is not the correct way to get a strong bond.
@@KitplaneEnthusiast I agree if it was a structural part, going onto structural laminations, if it was I would step back the layers in the main piece and then do a step out repair and vacum bagged to remove the excess resin. It depends on the application. Personally I would have made the hole bigger still and gone to the inside, for your application if I wanted a structural bond, as you are bonding on GelCoat, which is non-structural, it makes little difference. Just my view what do you think?
Did you do one on the other side to match? When I needed to do this on my road race motorcycles I would put the patch on the inside. Cut some cardboard to the radius I wanted on the outside apply packing tape and then lay down lightweight fabric that would easily form to the shape wanted. Then lay down extra layers as needed then fill the outside edges with epoxy and micro balloons, there isn't any strength in the epoxy. Sand smooth and prime. :D
Craig, I need to mention this more often, but I used to repeat in my videos that I am only showing you how I did. But keep in mind there are 100 ways to do the same thing. This was my method, and there are many other methods that will also reward you with perfect results.
is the blister going to disturb the airflow around the winds or exit as you increase speed?
There is another material we call mat, what you have is woven. Also why dont you steal roll it to get the air out?
What is the advantage of using fibreglass resin over epoxy resin for your initial layup?
It is actually epoxy resin.
@@KitplaneEnthusiast polyester is usually used in fiberglass isn't it? Just saying . Nice job though!
Surprised you fiberglassed over primer. Supposed to be glass to glass. Hopefully it doesn’t cause problems later but it is non structural.
One hundredth thumbs up.
Thank you!
Yeah, it is pretty typical to have to add these
There is no definitive definition of assault weapon. Anything I can attack with is an assault weapon