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daveleikam(at)wi.rr.com
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 Posted: Sun Feb 07, 2010 8:57 pm Post subject: Windshield fairing |
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I am about to make my windshield fairing. Are there any tips or pointers anyone would like to share before I begin?
I am using black dye in the epoxy.
Dave Leikam
RV-10 #40496
N89DA
Muskego, WI
do not archive
[quote][b]
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dave.saylor.aircrafters(a
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| Posted: Mon Feb 08, 2010 10:37 am Post subject: Windshield fairing |
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Couple things:
If you stagger the initial, narrower, strips as they begin to spread out on the flatter, vertical sides of the fuse, you'll avoid a lump in the middle of the lay-up. You'll see that if you follow the same technique as shown in the plans all the way from the middle of the windshield to the door frame, you end up with a LOT of fiberglass all concentrated at the center of the strip. That's not necessary. Spread the layers out so they go one above, one below, etc. Even staggering the layers, you'll end up with a high spot near the door frame, but it's manageable.
And, if you cut all those strips on a 45* angle to the edge of your cloth, it'll be a lot easier to manage them when you start working them into the layup.
Dave Saylor
AirCrafters LLC
140 Aviation Way
Watsonville, CA 95076
831-722-9141 Shop
831-750-0284 Cell
On Sun, Feb 7, 2010 at 8:53 PM, Dave Leikam <daveleikam(at)wi.rr.com (daveleikam(at)wi.rr.com)> wrote:
[quote] I am about to make my windshield fairing. Are there any tips or pointers anyone would like to share before I begin?
I am using black dye in the epoxy.
Dave Leikam
RV-10 #40496
N89DA
Muskego, WI
do not archive
| Quote: |
get="_blank">http://www.matronics.com/Navigator?RV10-List
tp://forums.matronics.com
_blank">http://www.matronics.com/contribution
|
[b]
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Jim Berry
Joined: 10 Jan 2006
Posts: 237
Location: Denver
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| Posted: Mon Feb 08, 2010 10:52 am Post subject: Re: Windshield fairing |
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To eliminate the high spot near the door frame that Dave mentioned I cut the first 4 layers full length, then shortened each additional layer by 1" at each end.
Jim Berry
40482
N15JB
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johngoodman
Joined: 18 Sep 2006
Posts: 530
Location: GA
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| Posted: Mon Feb 08, 2010 11:17 am Post subject: Re: Windshield fairing |
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I went with the aluminum fairing from M.L.Skunkworks. Worked out great.
John
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#40572 Phase One complete in 2011 |
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rv10builder(at)verizon.ne
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| Posted: Mon Feb 08, 2010 12:48 pm Post subject: Windshield fairing |
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You need to do another fiberglass video on EAA homebuilders site on how to do this technique correctly!!
Thanks for that info.
Pascal
From: Dave Saylor (dave.saylor.aircrafters(at)gmail.com)
Sent: Monday, February 08, 2010 10:32 AM
To: rv10-list(at)matronics.com (rv10-list(at)matronics.com)
Subject: Re: Windshield fairing
Couple things:
If you stagger the initial, narrower, strips as they begin to spread out on the flatter, vertical sides of the fuse, you'll avoid a lump in the middle of the lay-up. You'll see that if you follow the same technique as shown in the plans all the way from the middle of the windshield to the door frame, you end up with a LOT of fiberglass all concentrated at the center of the strip. That's not necessary. Spread the layers out so they go one above, one below, etc. Even staggering the layers, you'll end up with a high spot near the door frame, but it's manageable.
And, if you cut all those strips on a 45* angle to the edge of your cloth, it'll be a lot easier to manage them when you start working them into the layup.
Dave Saylor
AirCrafters LLC
140 Aviation Way
Watsonville, CA 95076
831-722-9141 Shop
831-750-0284 Cell
On Sun, Feb 7, 2010 at 8:53 PM, Dave Leikam <daveleikam(at)wi.rr.com (daveleikam(at)wi.rr.com)> wrote:
[quote] I am about to make my windshield fairing. Are there any tips or pointers anyone would like to share before I begin?
I am using black dye in the epoxy.
Dave Leikam
RV-10 #40496
N89DA
Muskego, WI
do not archive
| Quote: |
get="_blank">http://www.matronics.com/Navigator?RV10-List
tp://forums.matronics.com
_blank">http://www.matronics.com/contribution
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href="http://www.matronics.com/Navigator?RV10-List">http://www.matronics.com/Navigator?RV10-List
href="http://forums.matronics.com">http://forums.matronics.com
href="http://www.matronics.com/contribution">http://www.matronics.com/c
[b]
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orchidman
Joined: 10 Jul 2006
Posts: 277
Location: Oklahoma City - KRCE
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| Posted: Mon Feb 08, 2010 1:28 pm Post subject: Re: Windshield fairing |
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| rv10builder(at)verizon.ne wrote: | You need to do another fiberglass video on EAA homebuilders site on how to do this technique correctly!!
Thanks for that info.
Pascal
|
Better yet, go to one of Daves classes. Sure saved me DAYS of work and did it right the first time.
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dave.saylor.aircrafters(a
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| Posted: Mon Feb 08, 2010 1:48 pm Post subject: Windshield fairing |
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Sure, that would be great. Let EAA know you want to see more and maybe we can arrange a complete video. We did that while we were at AirVenture. They had a professional studio set up in a workshop and they were making several videos every day.
The technique with the plastic shown in the video would work fine on the windscreen. It makes things a lot neater. There's no reason you couldn't do a couple layers at a time in one sandwich. Or, if it's fairly cool in the shop, say, 60 or below, you could make a large section of sandwich and then cut your strips out of the sandwich. But it has to be pretty cool cuz it's a lot of resin to have laid out at one time. If it's too warm it might start to set up. The windscreen fairing takes several hours, and it's good to have some extra hands available. The strips are pretty long and can get kind of unruly. But the plastic makes it much easier.
(video on sandwich method here: http://tinyurl.com/yhe4upe)
Dave Saylor
AirCrafters LLC
140 Aviation Way
Watsonville, CA 95076
831-722-9141 Shop
831-750-0284 Cell
On Mon, Feb 8, 2010 at 12:30 PM, Pascal <rv10builder(at)verizon.net (rv10builder(at)verizon.net)> wrote:
[quote] You need to do another fiberglass video on EAA homebuilders site on how to do this technique correctly!!
Thanks for that info.
Pascal
From: Dave Saylor (dave.saylor.aircrafters(at)gmail.com)
Sent: Monday, February 08, 2010 10:32 AM
To: rv10-list(at)matronics.com (rv10-list(at)matronics.com)
Subject: Re: Windshield fairing
Couple things:
If you stagger the initial, narrower, strips as they begin to spread out on the flatter, vertical sides of the fuse, you'll avoid a lump in the middle of the lay-up. You'll see that if you follow the same technique as shown in the plans all the way from the middle of the windshield to the door frame, you end up with a LOT of fiberglass all concentrated at the center of the strip. That's not necessary. Spread the layers out so they go one above, one below, etc. Even staggering the layers, you'll end up with a high spot near the door frame, but it's manageable.
And, if you cut all those strips on a 45* angle to the edge of your cloth, it'll be a lot easier to manage them when you start working them into the layup.
Dave Saylor
AirCrafters LLC
140 Aviation Way
Watsonville, CA 95076
831-722-9141 Shop
831-750-0284 Cell
On Sun, Feb 7, 2010 at 8:53 PM, Dave Leikam <daveleikam(at)wi.rr.com (daveleikam(at)wi.rr.com)> wrote:
| Quote: |
get="_blank">http://www.matronics.com/Navigator?RV10-List
tp://forums.matronics.com
_blank">http://www.matronics.com/contribution
|
[b]
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http://www.matronics.com/Navigator?RV10-List |
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speckter(at)comcast.net
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| Posted: Mon Feb 08, 2010 2:16 pm Post subject: Windshield fairing |
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The downside of doing the poly method on a bench and then transferring it to the plane is that the whole layup can kick off on you if you move too slowly or the temp is too high. That is why laying up on the plane is preferable in my mind. It also allows you to adjust ply length to suit the area you are working in, such as Dave describes for staggering the layers along the door frame. Mix your resin in small batches and make sure they don’t kick off on you. However it is quite acceptable to have the lower layers of a layup start to cure while you are working on the upper layers. In a Glasair III for example the motor mount attach area has a layup of 25 ply. You start at the bottom and work continuously upward mixing the resin in small batches as you go.
Gary Specketer
From: owner-rv10-list-server(at)matronics.com [mailto:owner-rv10-list-server(at)matronics.com] On Behalf Of Dave Saylor
Sent: Monday, February 08, 2010 4:44 PM
To: rv10-list(at)matronics.com
Subject: Re: Windshield fairing
Sure, that would be great. Let EAA know you want to see more and maybe we can arrange a complete video. We did that while we were at AirVenture. They had a professional studio set up in a workshop and they were making several videos every day.
The technique with the plastic shown in the video would work fine on the windscreen. It makes things a lot neater. There's no reason you couldn't do a couple layers at a time in one sandwich. Or, if it's fairly cool in the shop, say, 60 or below, you could make a large section of sandwich and then cut your strips out of the sandwich. But it has to be pretty cool cuz it's a lot of resin to have laid out at one time. If it's too warm it might start to set up. The windscreen fairing takes several hours, and it's good to have some extra hands available. The strips are pretty long and can get kind of unruly. But the plastic makes it much easier.
(video on sandwich method here: http://tinyurl.com/yhe4upe)
Dave Saylor
AirCrafters LLC
140 Aviation Way
Watsonville, CA 95076
831-722-9141 Shop
831-750-0284 Cell
On Mon, Feb 8, 2010 at 12:30 PM, Pascal <rv10builder(at)verizon.net (rv10builder(at)verizon.net)> wrote:
You need to do another fiberglass video on EAA homebuilders site on how to do this technique correctly!!
Thanks for that info.
Pascal
From: Dave Saylor (dave.saylor.aircrafters(at)gmail.com)
Sent: Monday, February 08, 2010 10:32 AM
To: rv10-list(at)matronics.com (rv10-list(at)matronics.com)
Subject: Re: Windshield fairing
Couple things:
If you stagger the initial, narrower, strips as they begin to spread out on the flatter, vertical sides of the fuse, you'll avoid a lump in the middle of the lay-up. You'll see that if you follow the same technique as shown in the plans all the way from the middle of the windshield to the door frame, you end up with a LOT of fiberglass all concentrated at the center of the strip. That's not necessary. Spread the layers out so they go one above, one below, etc. Even staggering the layers, you'll end up with a high spot near the door frame, but it's manageable.
And, if you cut all those strips on a 45* angle to the edge of your cloth, it'll be a lot easier to manage them when you start working them into the layup.
Dave Saylor
AirCrafters LLC
140 Aviation Way
Watsonville, CA 95076
831-722-9141 Shop
831-750-0284 Cell
On Sun, Feb 7, 2010 at 8:53 PM, Dave Leikam <daveleikam(at)wi.rr.com (daveleikam(at)wi.rr.com)> wrote:
| Quote: |
I am about to make my windshield fairing. Are there any tips or pointers anyone would like to share before I begin?
I am using black dye in the epoxy.
Dave Leikam
RV-10 #40496
N89DA
Muskego, WI
do not archive
| Quote: | | get="_blank">http://www.matronics.com/Navigator?RV10-Listtp://forums.matronics.com_blank">http://www.matronics.com/contribution |
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[quote][b]
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velo
Joined: 22 Jul 2009
Posts: 15
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| Posted: Mon Feb 08, 2010 2:47 pm Post subject: Windshield fairing |
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Dave,
Thanks for the help. We too are about to start on the windscreen. What exactly is the “plastic”.
Thanks,
Rick
From: owner-rv10-list-server(at)matronics.com [mailto:owner-rv10-list-server(at)matronics.com] On Behalf Of Dave Saylor
Sent: Monday, February 08, 2010 2:44 PM
To: rv10-list(at)matronics.com
Subject: Re: Windshield fairing
Sure, that would be great. Let EAA know you want to see more and maybe we can arrange a complete video. We did that while we were at AirVenture. They had a professional studio set up in a workshop and they were making several videos every day.
The technique with the plastic shown in the video would work fine on the windscreen. It makes things a lot neater. There's no reason you couldn't do a couple layers at a time in one sandwich. Or, if it's fairly cool in the shop, say, 60 or below, you could make a large section of sandwich and then cut your strips out of the sandwich. But it has to be pretty cool cuz it's a lot of resin to have laid out at one time. If it's too warm it might start to set up. The windscreen fairing takes several hours, and it's good to have some extra hands available. The strips are pretty long and can get kind of unruly. But the plastic makes it much easier.
(video on sandwich method here: http://tinyurl.com/yhe4upe)
Dave Saylor
AirCrafters LLC
140 Aviation Way
Watsonville, CA 95076
831-722-9141 Shop
831-750-0284 Cell
On Mon, Feb 8, 2010 at 12:30 PM, Pascal <rv10builder(at)verizon.net (rv10builder(at)verizon.net)> wrote:
You need to do another fiberglass video on EAA homebuilders site on how to do this technique correctly!!
Thanks for that info.
Pascal
From: Dave Saylor (dave.saylor.aircrafters(at)gmail.com)
Sent: Monday, February 08, 2010 10:32 AM
To: rv10-list(at)matronics.com (rv10-list(at)matronics.com)
Subject: Re: RV10-List: Windshield fairing
Couple things:
If you stagger the initial, narrower, strips as they begin to spread out on the flatter, vertical sides of the fuse, you'll avoid a lump in the middle of the lay-up. You'll see that if you follow the same technique as shown in the plans all the way from the middle of the windshield to the door frame, you end up with a LOT of fiberglass all concentrated at the center of the strip. That's not necessary. Spread the layers out so they go one above, one below, etc. Even staggering the layers, you'll end up with a high spot near the door frame, but it's manageable.
And, if you cut all those strips on a 45* angle to the edge of your cloth, it'll be a lot easier to manage them when you start working them into the layup.
Dave Saylor
AirCrafters LLC
140 Aviation Way
Watsonville, CA 95076
831-722-9141 Shop
831-750-0284 Cell
On Sun, Feb 7, 2010 at 8:53 PM, Dave Leikam <daveleikam(at)wi.rr.com (daveleikam(at)wi.rr.com)> wrote:
| Quote: |
I am about to make my windshield fairing. Are there any tips or pointers anyone would like to share before I begin?
I am using black dye in the epoxy.
Dave Leikam
RV-10 #40496
N89DA
Muskego, WI
do not archive
| Quote: | | get="_blank">http://www.matronics.com/Navigator?RV10-Listtp://forums.matronics.com_blank">http://www.matronics.com/contribution |
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[quote][b]
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indigoonlatigo(at)msn.com
Guest
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| Posted: Mon Feb 08, 2010 2:51 pm Post subject: Windshield fairing |
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This may be too obvious C but make sure you etch your aluminum. It makes a huge difference in the adhesion strength. Score it with the sandpaper C clean it with the solvent C then etch and wash.
From: daveleikam(at)wi.rr.com
To: rv10-list(at)matronics.com
Subject: RV10-List: Windshield fairing
Date: Sun C 7 Feb 2010 22:53:18 -0600
I am about to make my windshield fairing. Are there any tips or pointers anyone would like to share before I begin?
I am using black dye in the epoxy.
Dave Leikam
RV-10 #40496
N89DA
Muskego C WI
do not archive
[quote]
ttp://www.matronics.com/Navigator?RV10-List
ronics.com
ww.matronics.com/contribution
[b]
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rv10builder(at)verizon.ne
Guest
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| Posted: Mon Feb 08, 2010 2:51 pm Post subject: Windshield fairing |
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I really do think having those videos are a great reference, I liked your presentation and based on the feedback I heard from a couple builders who came to your class it shows you do an excellent job explaining how to do these things.
As a reference for many I use those hotel cards, the ones one gets for the doors, and use them for spreading out the resin over the cloth the good thing about this is once they get dirty, which shouldn't be too often if one uses plastic to sandwich the cloth/resin, it can be tossed. I also so a whole lot of the spreaders at HF for a few dollars so certainly a great suggestion Dave makes about using them.
Thanks Dave!
Pascal
From: Dave Saylor (dave.saylor.aircrafters(at)gmail.com)
Sent: Monday, February 08, 2010 1:44 PM
To: rv10-list(at)matronics.com (rv10-list(at)matronics.com)
Subject: Re: Windshield fairing
Sure, that would be great. Let EAA know you want to see more and maybe we can arrange a complete video. We did that while we were at AirVenture. They had a professional studio set up in a workshop and they were making several videos every day.
The technique with the plastic shown in the video would work fine on the windscreen. It makes things a lot neater. There's no reason you couldn't do a couple layers at a time in one sandwich. Or, if it's fairly cool in the shop, say, 60 or below, you could make a large section of sandwich and then cut your strips out of the sandwich. But it has to be pretty cool cuz it's a lot of resin to have laid out at one time. If it's too warm it might start to set up. The windscreen fairing takes several hours, and it's good to have some extra hands available. The strips are pretty long and can get kind of unruly. But the plastic makes it much easier.
(video on sandwich method here: http://tinyurl.com/yhe4upe)
Dave Saylor
AirCrafters LLC
140 Aviation Way
Watsonville, CA 95076
831-722-9141 Shop
831-750-0284 Cell
On Mon, Feb 8, 2010 at 12:30 PM, Pascal <rv10builder(at)verizon.net (rv10builder(at)verizon.net)> wrote:
[quote] You need to do another fiberglass video on EAA homebuilders site on how to do this technique correctly!!
Thanks for that info.
Pascal
From: Dave Saylor (dave.saylor.aircrafters(at)gmail.com)
Sent: Monday, February 08, 2010 10:32 AM
To: rv10-list(at)matronics.com (rv10-list(at)matronics.com)
Subject: Re: Windshield fairing
Couple things:
If you stagger the initial, narrower, strips as they begin to spread out on the flatter, vertical sides of the fuse, you'll avoid a lump in the middle of the lay-up. You'll see that if you follow the same technique as shown in the plans all the way from the middle of the windshield to the door frame, you end up with a LOT of fiberglass all concentrated at the center of the strip. That's not necessary. Spread the layers out so they go one above, one below, etc. Even staggering the layers, you'll end up with a high spot near the door frame, but it's manageable.
And, if you cut all those strips on a 45* angle to the edge of your cloth, it'll be a lot easier to manage them when you start working them into the layup.
Dave Saylor
AirCrafters LLC
140 Aviation Way
Watsonville, CA 95076
831-722-9141 Shop
831-750-0284 Cell
On Sun, Feb 7, 2010 at 8:53 PM, Dave Leikam <daveleikam(at)wi.rr.com (daveleikam(at)wi.rr.com)> wrote:
| Quote: |
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dave.saylor.aircrafters(a
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| Posted: Mon Feb 08, 2010 3:15 pm Post subject: Windshield fairing |
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We use a very thin painter's plastic:
http://www.acehardware.com/product/index.jsp?productId=1279480
That's a big box and it would last a LONG time. Just about any kind of plastic drop cloth would work. The plastic in the video was much thicker than what we normally use, and it was still easy to work with.
Dave Saylor
AirCrafters LLC
140 Aviation Way
Watsonville, CA 95076
831-722-9141 Shop
831-750-0284 Cell
On Mon, Feb 8, 2010 at 2:29 PM, Richard Barnes <rickbarnes(at)highlanddental.com (rickbarnes(at)highlanddental.com)> wrote:
[quote]
Dave,
Thanks for the help. We too are about to start on the windscreen. What exactly is the “plastic”.
Thanks,
Rick
From: owner-rv10-list-server(at)matronics.com (owner-rv10-list-server(at)matronics.com) [mailto:owner-rv10-list-server(at)matronics.com (owner-rv10-list-server(at)matronics.com)] On Behalf Of Dave Saylor
Sent: Monday, February 08, 2010 2:44 PM
To: rv10-list(at)matronics.com (rv10-list(at)matronics.com)
Subject: Re: Windshield fairing
Sure, that would be great. Let EAA know you want to see more and maybe we can arrange a complete video. We did that while we were at AirVenture. They had a professional studio set up in a workshop and they were making several videos every day.
The technique with the plastic shown in the video would work fine on the windscreen. It makes things a lot neater. There's no reason you couldn't do a couple layers at a time in one sandwich. Or, if it's fairly cool in the shop, say, 60 or below, you could make a large section of sandwich and then cut your strips out of the sandwich. But it has to be pretty cool cuz it's a lot of resin to have laid out at one time. If it's too warm it might start to set up. The windscreen fairing takes several hours, and it's good to have some extra hands available. The strips are pretty long and can get kind of unruly. But the plastic makes it much easier.
(video on sandwich method here: http://tinyurl.com/yhe4upe)
Dave Saylor
AirCrafters LLC
140 Aviation Way
Watsonville, CA 95076
831-722-9141 Shop
831-750-0284 Cell
On Mon, Feb 8, 2010 at 12:30 PM, Pascal <rv10builder(at)verizon.net (rv10builder(at)verizon.net)> wrote:
You need to do another fiberglass video on EAA homebuilders site on how to do this technique correctly!!
Thanks for that info.
Pascal
From: Dave Saylor (dave.saylor.aircrafters(at)gmail.com)
Sent: Monday, February 08, 2010 10:32 AM
To: rv10-list(at)matronics.com (rv10-list(at)matronics.com)
Subject: Re: RV10-List: Windshield fairing
Couple things:
If you stagger the initial, narrower, strips as they begin to spread out on the flatter, vertical sides of the fuse, you'll avoid a lump in the middle of the lay-up. You'll see that if you follow the same technique as shown in the plans all the way from the middle of the windshield to the door frame, you end up with a LOT of fiberglass all concentrated at the center of the strip. That's not necessary. Spread the layers out so they go one above, one below, etc. Even staggering the layers, you'll end up with a high spot near the door frame, but it's manageable.
And, if you cut all those strips on a 45* angle to the edge of your cloth, it'll be a lot easier to manage them when you start working them into the layup.
Dave Saylor
AirCrafters LLC
140 Aviation Way
Watsonville, CA 95076
831-722-9141 Shop
831-750-0284 Cell
On Sun, Feb 7, 2010 at 8:53 PM, Dave Leikam <daveleikam(at)wi.rr.com (daveleikam(at)wi.rr.com)> wrote:
| Quote: |
I am about to make my windshield fairing. Are there any tips or pointers anyone would like to share before I begin?
I am using black dye in the epoxy.
Dave Leikam
RV-10 #40496
N89DA
Muskego, WI
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