Let’s continue our work on the rear fuselage.
You will have two top rear fuselage plates; they have a notch in them which goes around the rudder post. They are laminated together as we’ve done for other pieces.
After laminating the top rear fuselage plates together using a high quality wood glue, the resultant piece is sanded and then glued to the foam using gorilla glue or 2216 glue. The edge is also routed round; this is easily done either before or after gluing to the foam.
The rear rudder post receives a 4″ strip of 2 oz glass on each side. After sanding, we apply some lightweight spackle over the glass to smooth the joint.
Carbon fiber cloth is cut to fit over the top and the bottom plate. Each piece is, in turn, epoxied in place. The overlap area should be at least 4″. Cut around the exit point for the rudder cable.
There are two pieces of vertical stabilizer foam: the main and the front piece. They are glued to the rear rudder post and to the front rudder post using gorilla glue. The front piece is also ‘pinned’ into the rear fuselage foam using scrap pieces of 1/4″ aluminum tubing: a 12″ piece and a 6″ piece. Drill a quarter inch hole, clean the scrap pieces of tubing; and insert into the holes using water mist and gorilla glue.
The above photo shows the carbon fiber cloth reinforcement which was epoxied over the wood and fuselage. A bottom piece is also epoxied over the bottom wood piece; the overlap area should be at least four inches.
After the glue sets, we route a round edge to the top and front edges of the vertical stabilizer, and then apply a 4″ fiberglass reinforcement over all edges, and also over all tube / foam glue joint areas. The front foam piece is also glassed to the fuselage using 4″ pieces on each side and around the front.
There are three more pieces of wood to be installed in the rear fuselage. The first is the lower front fuselage reinforcement. The pieces are laminated together as shown:
This piece fits on the lower bottom of the fuselage, where it butts to the cabin. The notch allows proper operation of the elevator bellcrank. In order to install it, the foam is cut out exactly 1/2″ (the thickness of the piece), and the part is Gorilla glued in place.
In order to make it easy to glue, and in order to ensure that the Gorilla glue didn’t get over the fuselage, the fuselage is lifted into place.
The view on the floor:
Next we laminate the lower front load spanner.
And we place it over the bottom of fuselage, using a sharpie pen to mark areas to be cutout.
24 hours later, after the 2216 glue has set, sand the entire surface smooth. Large gaps must be filled with additional 2216 glue. Small gaps (less than 3/16″ depth) may be filled with spackle. There was a slight warpage in the wood piece, it was also sanded out. Note that the front piece has also been sanded to uniform fit perfection.
The next piece of wood to be installed is the trim ring around the cargo area.
The two pieces are laminated together. Here they are, before lamination:
The location of the foam cutout is marked with a Sharpie.
After the glue is set, excess glue is cutout and removed.