Chapter 24 Armrest/Seats/Covers/Fairings

LG/FW Cover (forward of the Header tank) is covered after the Armrest/seatbacks section

Lower strake fairing (see chapter 21)

Upper strake fairing (in late May-2010-see chapter 21)

LG to fuselage fairing  (see chapter 9)

Wheel pants (see chapter 9)

Jan. to Feb. 2008

This chapter really is a continuation of chapter sixteen and so I did this work right after the controls. This is work done before the strakes and turtleback, so the fuselage is turned on the side on (secured) saw horses.


The first two pictures show the location of the AN3 bolt to take off the CS-124 and where the fuel line runs. Later, I cut the armrest for access to get to the AN3 bolt. The third picture shows the completed right rear armrest. The next picture shows the front right side to the armrest with the inner surface glassed and cut. I made the half thickness cuts by turning the fine cut blade over and running the blade with the teeth reversed. This was gentle to the foam. There were more cuts on the back armrest sides and where the armrest tapers down, I needed some angled cuts to make the curve shape contour. In the last picture, I laid down some plastic over the side of the fuselage and the armrest supports. Then, I put some 5 minute epoxy in the cut lines and quickly placed the armrest side down in position and laid boards on it and then some bricks for cure to hold the curve. Later, I added some micro into the cut lines and some UND strips across the cut lines, and reapplied the plastic and weighed it down again to cure. I did not flox the wood armrest to the armrest side at the final install, for fear of flox dripping down onto the controls. Before the final install, I sanded all of the foam off at the points where the passengers hips would touch. I only stopped when I could see the inner glass. Looking back to the third picture, I used some masking tape to bridge the small gap between the fuselage and the bottom of the armrest side. I laid the armrest down on a piece of plastic and marked the outline and added the overlap to that. I wet a two ply BID layup on the plastic and transferred it to the armrest/side with micro on the corner and edge of the masking tape (at the bottom) and then peel plied the edges. The black line is the line marked on the plastic to show the corner of the armrest to line things up for placement. I did not try to overlap at the front and back of the armrest. I later applied BID tape (plastic backed) there. The picture does not show the BID tape in the armrest to fuselage corner. The result of this is that I can prime and paint the armrest and have a smooth curve surface that will not need upholstery work. 


The first picture just shows after the 5 minute epoxy. The second picture shows how that I glassed the front and back edges to prepare for the use of BID tape. The reason for the puzzle pieces in the third picture is to gain some more storage space up front for "stuff". The larger funny looking space has a slot for the roll cable and the depression with the funny look is for the travel of the controls. The rest of the pieces finish the enclosure of the space. I just made the big piece in cardboard and then in foam. I repeated the process for the other parts. You can see the pocket, but I would not call mine a map pocket. I made a flush cover for that pocket to allow support for my elbow. The cover is not on in the last picture, because the fuselage is upside down in that picture. The fresh air vent is covered in ch. 21. When I prime the bottom of the fuselage, I will flip the plane and finish the bottom of the strake area. In the last picture, I have an access panel cut out to be able to guide the pulling of wires down the electrical conduit. The next to the last picture shows the number of cuts needed to curve the seat bottoms. I extended the front seat bottom back a little to raise it up a wee bit and to allow better but contour. I also added a seat back like the rear seats to allow for adjustment of back support and that is covered below. 

Pic#1: I added UND reinforcements (4ply) on the bottom side of the front seats, because they will get stepped on.
Pic#2: The seats are removable. I placed Tee nuts with some wax in the holes and glassed over them. The hinges were cut out and labeled for each spot and used to exactly place the Tee nuts. One side of the hinge is glassed onto the fuselage.
Pic#3: The front seat bases are contoured.

Pic#4: The front seat base with Zolatone.


Pic#1: The contraption that is shown her is a removable seat prop base and a removable insert. The insert 
Pic#2: I contoured the seat by adding side supports.
Pic#3: This is the Zolatone covered front seat back (upside down)
Pic#4: This is the throttle quadrant console covered in chapter 17 (ready for Zolatone).


The LG/FW cover has two main purposes. To support the rear seats in a slightly forward position and to provide extra protection to the fuel line hoses connected to the fuel pumps in the header tank.
Pic#1: This is the header tank.
Pic#2: The heat duct has been cut off. Since I have an water cooled engine, the water hoses are able to be routed through the LG bulkhead (with protective sleeves). I needed the rear seats to rotate forward about 1.5 inches to make room for the fuel lines and for the roll function servo motor. The push/pull throttle cable is not shown.
Pic#3: It looks silly to show the cardboard mock up, but it really helps. I cut the holes to check for where to add aft supports to contact the LG bulkheads. The conduit channel above the heat duct has some glassed pieces. I am removing them, and replacing them with two push/pull cables. That will make more room for the wiring to the IVO system and the option to add a "fat" wire (copper clad aluminum wire) for placement of one of the batteries in the nose as needed for CG adjustment.
Pic#4: After, I did the layups on both sides, I marked the positions for aft supports to the LG bulkhead. Then I drilled 1/8th inch holes and placed finishing nails to hold the supports and check for fit. I had to trim a little and also I had a gap to flox in later. 
The outer edges are cosmetic and so I bridged the gap with some masking tape, before glassing from the fuselage sides to the edge of the cover. The cut line is marked and the aft side of the cover has been cut. I placed clingwrap to release the cover, after the outboard piece is glassed. My access panel to remove the controls from the FW is on the inboard side of the armrest under the edge of this cover. That is not a problem.
Note: In the last pic, the header tank has duct tape on it. This is for the leak test with water. I did not put the fuel pumps in water. The leak test was a complete sucess.
Pic#5: This is after the first coat of Zolatone. I ran out of Zolatone.