Chapter 5, Fuselage Sides

In chapter 5, We have to build the fuselage sides. These two sides will then be joined to the bulkheads that were built in chapter 4. The fuselage sides are made from 3/8" PVC foam with localized foam buildups which will allow the fuselage to be formed into a more round shape. The sides are glassed over a curved jig so that the correct shape is achieved in the completed sides.

Nov 14-15, 1998, building the longerons

Fuselage side longerons curing while being held to their correct final shape by the jigs. The jigs will be eventually positioned vertically to support the fuselage sides at their correct curvature. The longerons are later installed in the fuselage sides, conforming to the sides curvature.

Nov 21-22, 1998, Building the jigs and cutting the sides

Saturday, I purchased the Masonite and cut the fuselage side jigs. Sunday I pieced together the pieces that make the exterior of the fuselage sides. Left picture shows how I cut the foam using the jig as a template. Right picture shows the exterior foam sides already cut to shape. I'm still gluing the foam pieces together, which are held with masking tape.

BTW, the parts are held together by the tape at only one side, this way, you can "flip" one of the pieces over the other, apply epoxy to the joint and then "flip" the foam pieces back to their final configuration to permanently glue the pieces.

Nov 26-29, 1998, building the fuselage side jig and the shaping the sides

Voila, the jigs are built and all foam for the sides are cut and fitted. What a busy holiday weekend (thanks to my Carol), got to build all this and also add about four hours flying time to 309CM. Building like this is fun, but yes, we don't have kids yet. Well, hopefully, this is going to change next year (thanks to my Carol and, well, me). Now, all I have to do is epoxy the foam in place and lay-up the glass (Yeah, right).

Dec 5-6, 1998, gluing the foam and glassing the sides

After gluing the foam buildups, I sanded and glassed the sides. I did each side on different days and without affixing the longerons. It still took me 5 hours per lay-up. I'm definitely slow but they came out nice. The two pictures show the right side being glassed and the final result. The second one came out much nicer, I guess that practice pays off.

Update through 8/31/99: Although progress has been slow, I got the longerons and other wood pieces on the sides. I need to add the foam and glass to the spar/landing gear reinforcing area and then trim the sides. The pictures show the progress so far. The Mooney's annual and work will keep me away from the project for a couple of months but I will be back !!!

Update through 3/24/2003: A couple of months turned to three+ years. But what the heck, I’m back. See, nice thing about plans built, no big investment to worry about. Well, I got the Mooney all fixed up and even took it to Oshkosh last year it flies very nice and it is actually quite roomy as compared to the Cozy. But I want Cozy. In January our baby boy was born and now I finally decided to slowly get back to Cozy. I cleaned and inspected all my equipment and finished the spar/landing gear reinforcing area. Popped the halves out of the jigs and was able for the first time in along time to see them from a different perspective. I will cut the sides to length and finally start Chapter 6.

4/9/2003: I installed Vance’s fuel gage sights. Sides are trimmed and ready for Chapter 6. Yahoo!

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