Europa #435 G-RODO Build Journal - 2002 09

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10 While trailer is out on the grass (to let tree surgeon in with his trailer) mark out a centre-line on the slabs between the wheel lines, to show where tow hitch should be.
11 Photograph FL1 / FL2 / FL3 filing clamp.
12 Draw-file inside of lightening holes on FL1 / FL2 with half-round swiss file and check all other edges for cross-wise scratches, draw-filing out as needed. Finish FL2s and start on FL3. 351.5
16 Photograph end of FL1 / FL2 / FL3 filing clamp.
17 Finish filing FL3s. Linish all FL1 / FL2 / FL3 with 320 grit paper on belt sander. Rub all over with Scotchbrite. Degrease in acetone and spray with zinc chromate primer, fading off at ends to be embedded in flaps - that will get Scotchbrite'd again before glassing in. 354.5
28 Start to set up for port flap root closeout. The jig at that end comes loose with a slight accidental knock, so re-fix it with Isopon. Draw-file all edges of FL7 pieces. Check position of FL1 & FL3 and apply masking tape flush with flap outer surface. With Scotchbrite clean off zinc chromate from FL1 area to be embedded in closeout. Check sizes of BID in manual against workpiece and decide I need 440mmx140mm for root, with 280mmx140mm for supplementary plies. Mark and cut 3 full-length and 3 part-length pieces of BID. Mark positions of FL7 and end of short BID layer on foam surface. About 19C and 64%RH. Mix 1 stroke epoxy with 1 dose q-cell for micro slurry. Would have been easier if glass surfaces were masked off, but not too hard to clean the micro slurry off them where necessary. Mix 2 strokes epoxy, apply and wet out first 2 layers of BID. Struggle to cut slot in glass for FL1; eventually have to use end of slightly inserted FL1 as anvil to cut against from below. Next time will try putting a piece of foam under the slot to hold the glass in position and cutting into that. Mix 2 strokes epoxy and 3 doses flox. Abrade FL1 again with Scotchbrite. Trowel flox onto back of FL1 with it inserted and tilted out. Abrade FL7 and trowel flox onto rear. Position and trowel more flox around it and FL1 to make fillets. Mix 4 strokes epoxy and apply first short layer of BID. Scissor trimming is quite tricky on each layer as the template prevents good access for knuckles, and the layup tends to get dragged out by the scissors. Repeat with 2nd & 3rd FL7s and short BID layers. Almost run out of flox, but a small scrape left for a sample. Rib flange getting quite heavy with epoxy now, and tending to sag away from top surface, even though trimmed quite close. It would probably be easier if the flap was vertical and the root rib horizontal. Apply last full-length BID piece. Epoxy getting slightly more viscous and not wetting out so well, so mix 1 more stroke of epoxy and wet out final BID layer. Cut green peel-ply into strips and apply. Upper flange still wanting to sag in a couple of places, so clip it up with bulldog clips, keeping them isolated with more peel-ply in small strips. After dinner, erect curing tent and leave fan heater on 3, giving about 29C and 34%RH. 360.2
29 Turn off heat in curing tent. Closeout looks well cured.

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