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Building Integrity
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Date:  10-14-2013
Number of Hours:  7.00
Manual Reference:  ch 21
Brief Description:  Bottom skins attached

I spent the first hour going over the strake skin to fuselage/spar joint making sure the fit was exactly where it needed to be according to my wing alignment yesterday. (This is where i give a shout out to Joe Coraggio for awesome advise and a copy of the install plans. You rock dude!)
I used the freaking coolest stands from Home depot to get the position Exactly right, then prepped everything, used 30 minute micro and bonded the skins in place. While these cured I cut out 6 small round foam discs to fill the bolt access holes on the forward face of the spar and laid up 2 plies of glass over each and peel plied them. FYI I am doing every layup in here extremely wet and in multiple layers to make every effort possible to avoid leaks.
I mixed up a surprising amount of wet flox to fill all voids. The 30 minute micro was a temporary bond and all the gaps needed to be filled prior to the BID tape being laid.
Now here is where I am doing things differently. PIN HOLES are straight from Satan himself. Invented by Lucifer. I will take every extra measure of precision here in order to avoid the Devil.
The strake skin to spar connection is supposed to be a flox joint with 1 ply BID Tape. However, Since the skins on the plans strake are suppose to lap onto the spar and I don't have that convenience, I will be adding 2 plies of BID at every joint. This is where my method changes: I fill EVERY void with wet wet flox, remove ALL air pickets, then peel ply the flox. NO glass. After this partially cures, I remove the Peel Ply, sand the surface, spread another bead of flox and then lay up my BID Tape. The benefit is that you have a SOLID wall of Flox that is already cured and not going anywhere or "developing" any pin holes. And if it DOES, then the second layer of Flox and 2 plies of BID WILL take care of it. So here's to step 1, the flox joint!
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Strake bottom in position

Strake bottom in position

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bolt access holes filled

bolt access holes filled

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Both skins microed in place

Both skins microed in place

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