Many of the flat panels have cutouts and edges that will not be bonded to anything. These include bulkhead holes, hatches, inspection port holes, and seats.
These edges need to be sealed well since exposed end grain is susceptible to dinging and liquid absorption.
Some of the holes will be fine with 3 or 4 coats of epoxy. Areas with high access and potential wear should be toughened with glass or thickened epoxy. Russell's epoxy book covers these techniques.
Next time, I would consider sealing these before glassing the faces so that drips or runs would be less of an issue. Careful brushing with a small foam brush can still be tricky. As the grain absorbs the epoxy, I tried to hit it a couple times on the first coat. Small amounts of epoxy can be accurately placed with a syringe.
The cockpit seats and backs are rounded over before glassing so that the glass can overlap the curves. The seat backs will have their top edge exposed. The sides of the seat backs form the front of cubby holes, so they need the edges softened as well. I will be glassing the backs with the more square corner first. This will allow the glass from the front that laps over the curve to seal the square edge better.
Edge of seat.
Seat back. The top is closest. The rounded edge is access to storage behind the seat.
Some of these edges might benefit from a trim piece. I'll have to see later on.
Task time: 18 hours (last four days)
Total project time: 75 hours
Total project time: 75 hours
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