Chapter 1 - 4, Fuselage Assembly
Left: The primary epoxy system for my ERacer was Aeropoxy 2032/3660
Right: My epoxy ratio pump. I used a 60watt bulb and a cover box to keep things warm in the winter.
Left: I started with the Bulk head chapter. This was the first bulkhead that I completed so many years ago.
Right: The Divinicell Foam fuselage sides..I first started using a knife to carve it out but quickly changed to a router for a much smoother surface.
Left: This shows the wood stringer being bonded to the fuselage side and the foam being curved to shape prior to glassing over all of it.
Right: My daughter standing by a completed fuselage side.
Left: A trial fit of the fuselage sides positioned with the firewall bulkhead.
Right: The fuselage sides being epoxied together with front bulkhead, instrument panel, and seatback. The structure is held together with braces and large rubber bands. The Firewall is not glued in at this time.
Left: This is the 3" foam being carved out to form the fuselage bottom.
Right: Starting the initial glassing of the bottom foam.
Left: After the bottom is glued into position, We flip it on its side to begin the shaping.
Right: Now the aircraft has entered what we call the "boat stage". All your friends and neighbors will think you are building a boat.
Here are two similar shots, the left with out the outer glass skins and the right one after laying the glass on the outside of the fuselage.
Left: re-inforcement tapes are glued in to further connect the bulkheads and the fuselage sides.
Right: I chose to mount a throttle hardpoint on the left side of the fuselage Note the trim lever in position and seatbelt hardpoint on the lower stringer.
Left: The throttle quadrant, trim lever and main control stick installed as well as the covers over the seat. there is a small area under each seat for storage.
Right: Control stick
Pic showing left consul installed.
Seat back head rests with shoulder harness hardpoints installed into fuselage.
The firewall is made of Bi-directional layers of glass and epoxy over Aircraft grade plywood covered in fiberfrax and then Aluminum sheet.
Forward side of firewall after installation with aileron cables routed through.
Aft side of firewall with engine mount installed as well as the rudder cable pulley mounts.
The Upper fuselage assembly is covered in the " Chapter 9 & 13 " tab.