On a related note we had our annual Young Eagles event last Saturday. That's when we volunteer our time, airplanes, and fuel to fly young kids from 8 to 16 years old. I flew 14 kids on Saturday and had a blast doing it. Those kids are so much fun!
|First things first, here is the 9A sitting with other airplanes at the Young Eagles event on Saturday. The airplane before it should look familiar as I posted several pictures of it recently. It is Greg's and was in the same paint shop as mine.
|Ok, so in this picture you can see the restriction in the right side. Its hard to see the top part but believe me its restricted.
|Here I put a few lumps of clay on top of the plenum and then put the top cowling back on to measure how much room I have between the two.
|Then I mix up some pourable foam and make a mess...
|Another view of the mess
|Starting to trim down the mess to a shape I can work with.
|This is the foam product that I used.
|Ok, foam is now sanded to the shape I want.
|Now I lay up 4 layers of fiberglass over the foam. You will notice I used a lot of packing tape as a sort of mold release for both the foam and the fiberglass.
|In this picture I have trimmed up the cured fiberglass, removed the foam, cut the plenum under the fiberglass away, and "glued" the new fiberglass piece in. I used an epoxy/flox mixture to glue the two pieces together.
|Another view of the two pieces but this is after they had set up and I had done a little sanding on the final assembly.
|This is the section of the old plenum top that I cut out. You can see the circles where I marked the clay locations and heights.
|In this picture you can see where I cut the old top out and glued in the new. All that's left now is a little sanding and maybe a layer of micro or two to clean it all up.