March 1, 2012
After some modifications, the my first nose gear fairing doesn't fit. So, we're doing it again. Because some of you wanted to see more detail of how these fairings are made I'll put more pictures in this time.
Plain old modeling clay is what we start with. Cutting it into strips makes it easier to lay up and doesn't require as much pressure to shape it.
shaping is simply a matter of laying up the clay followed by push, squeeze, rub and smooth.
continue to shape until you have the rough shape you want. Next, smooth out the edges and rub the surface until it is relatively smooth.
When you are satisfied with the shape and the smoothness of the clay, apply fiberglass cloth and resin to the required thickness.
A layer of dacron over the fiberglass application will help smooth out your surface and reduce sanding.
The part can cut free (here at the back or trailing edge) and cut to shape then, drilled and made ready for paint.
On the bar metal of the step I sprayed self etching primer followed by a thick coat of primer surf acer. Now it's ready for sanding to take down that thick primer coat.
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