Soaring Break and Greg’s in the Garaggio

On short notice, I took a week off of working on the Defiant project. A friend of mine was coming to Phoenix to do a commercial glider add-on, so I invited myself along on the adventure. It was about a week of really fun flying. I highly recommend it. After my soaring sabbatical, it wasContinue reading “Soaring Break and Greg’s in the Garaggio”

Lower Cowl Mold, times two

The lower cowl geometry doesn’t lend itself well to making it a single piece mold. The centerline scoop/tunnel/boat tail has geometry that would “capture” the plug, and subsequent parts, in the mold if it was laid up as a single piece. You can still do a single piece mold, but there are some draw backs.Continue reading “Lower Cowl Mold, times two”

We have a Cowl Mold; Inspired by Sid

The last few days, when I have been looking at the rear cowl, I have thought that the trailing edge shape reminded me of something, but I couldn’t figure out what. Turns out, it is the character Sid from the cartoon movie, Ice Age. While I am fairly certain this destines Brian’s Defiant to henceforthContinue reading “We have a Cowl Mold; Inspired by Sid”

Prepping for Mold Making with Jodi

On Monday, I got to the point in contour sanding and surfacing on the cowl where I was struggling to find flaws that needed to be fixed. Don’t get me wrong, there were still minor flaws, but most of them small enough that I would be liable to go backwards instead of making improvements ifContinue reading “Prepping for Mold Making with Jodi”

New Plan for the Aft Cowl

Last week Thursday, before our trip to Kanab, I got the layup on the lower aft cowl done. What an exercise in frustration. I have done quite a few layups in my building history, but this one made me feel like it was the first time I had ever seen epoxy or cloth. The planContinue reading “New Plan for the Aft Cowl”

About to layup Lower Aft TCSN1

The last post we started a right side lower aft engine cowl, say that 5 times fast, and got it to a point where the foam shape mostly replicated the left side. Since then, I spent a bit more time adding, sanding, and shaping foam using my handy templates derived of 3D scanning to improveContinue reading “About to layup Lower Aft TCSN1”

Replicating Cowl Shape with a hybrid low and high tech method

Replicating the lower cowl shape is moving right along. In the last post we discussed how it was going to be more difficult than the top was to duplicate and mirror since it is more complex. One of the benefits of blogging and posting all about this project is the constructive suggestions I receive. ThomasContinue reading “Replicating Cowl Shape with a hybrid low and high tech method”

More Challenging, but solvable

Today was further proof that the lower cowl certainly is more challenging than the top. Even though I have determined some defining characteristics of the cowl and come up with a plan for the overall approach, it is still a challenge to blend these shapes and features together. It isn’t always intuitive how to blendContinue reading “More Challenging, but solvable”

Lower Cowl Challenges and Features

Update to “This Sucks, But not enough,”: From the last post, there was a lot of discussion on Facebook about my vacuum bagging failure, which is great. My main goal in blogging is to share my learnings with other interested people. There is a treasure trove of information in the Facebook comments, and once IContinue reading “Lower Cowl Challenges and Features”

Rear Engine Top Cowl

This is going to be a bit of a longer post, so please bear with me. I am going to try to get the blog up to date as of today, then keep it current going forward…. WHAT??? It could happen. As I mentioned in a previous blog post, the cowls don’t fit. Neither frontContinue reading “Rear Engine Top Cowl”