Curved areas like where the vertical fin meets the top stringers of the fuselage and around the rear windows are a bit challenging because the tape doesn't want to bend around corners. We used bias cut, 4" tape in those areas.
With the first coat of Poly Brush on, we will start the taping process as outlined in the Poly Fiber manual. Basically, you have to apply reinforcement tapes any place where there is a hard point. Longerons, stringers, door flanges, window openings, etc., all must have reinforcement tape applied.
Here is the top looking from the tail forward along the top stringers and
longerons:
Curved areas like where the vertical fin meets the top stringers of the
fuselage and around the rear windows are a bit challenging because the tape
doesn't want to bend around corners. We used bias cut, 4" tape in those
areas.
Showing the detail around the window opening:
Here is the right side aft of the cargo door.:
You can see at the tail I've already started making the frames for the
inspection holes.
You will need some inspection holes to gain access for connecting things or performing inspections, so you will need a frame of some sort to attach a cover to. If it's just a simple inspection hole, there are round plastic rings to use and a clip in place cover. If you need more room like back at the tail where all of the elevator and trim tab cables hook up, you will need a larger opening. These are best made out of .032 aluminum so the inspection cover can be screwed to it.
The proto-types have an 8" X 8" opening. I have an electric trim servo in my tail so I made my access hole 8"X 12" so I can get to everything. The access rings were made from aluminum and were shaped to fit the longeron. There was identical ones made for both sides so I can access the area with both hands if needed.
These metal access hole frames were glued to the fabric using PlioBond contact
cement. I also made a metal round ring for the area where the forward
horizontal stabilizer mount comes through because that inspection hole cover
has to be split or at least have a slot cut in it to get around the front
tube of the stabilizer:
The little rectangular piece is a mounting place for the identification
plate which will be pop-riveted on later.
Here is the ceiling area. Note that an inspection ring was put where
I need access to mount the antenna and hook up the coax cable:
I also installed an inspection ring on the inside under the front door flanges
where the fuel line bulkhead fitting is:
The plastic rings were simply glued on with some Poly Tak.
Inspection rings were also installed at each gang pulley location on the fuselage bottom.
All of the inspection rings were then covered with fabric patches as shown in the Poly Fiber instruction manual.
Click here to go to Fabric Covering page 7