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  1. P

    Single-door cabin?

    I experimented with different hammers and biggest was a long way from best. A sharp point and a full length handle won the day. For my Cozy canopy I carry a tack hammer (4 oz head) where I sharpened one end.
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    Horrible news from Vans Aircraft

    The following proves I'm terrible at cocktail parties... here's a too long post. Standing outside the company we are reading tea leaves. So far we are using common sense. To move beyond common sense, consider the research papers of the Federal Reserve. In 2023 the KC Fed has been looking at...
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    Stainless Steel Firewalls

    I prefer "ceramic paper" over Fiberfrax. This is a product used in ceramic and glass kilns and handles temperatures at least equal to FiberFrax. Easy to get (Amazon), easy to work with, it is an underlayment for another covering, possibly stainless steel sheet or TeknoFibra (below). I secure...
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    Work rules / practices

    Here's a shop tip - silicone baking trays. No scratches, a lip to keep things from rolling off and throw it in a dish washer if it gets dirty. No regrets. Here's a bunch for less than $4. 1pc Swiss Roll Cake Mat - Temu
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    Structural Epoxy - Aeropoxy Exotherm Test (Experiment)

    Regarding Raka - I've had good luck with their non-blushing "tropical" hardener. The test layups cured to something significantly stronger than West 105+206, and it is great in wetting out fibers. After methodical prep the Raka worked for a 3-ply layup for a large-ish panel (2' x 2') , even...
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    Issue with Sonerai Plans

    I don’t think much of the thread title. I got interested in EAB while in Hartford. There were Pratt & Whitney engineers who picked Sonex specifically due to the quality of the plans. The ones who need sympathy are those building from construction manuals until they get stranded by a failed...
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    Advice on Paint for New Purchase

    Above are the requested comments about UV protection. I'll add that modern top coats are remarkably durable and chemical resistant - well worth it to have the plane graduate to real paint. I'd say the collective experience of Cozy builders is to not fear DIY. The professionals have done a few...
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    Raptor NG Discussion

    Re Marc's Jeff Kerlo question..... I met Jeff at Sun N Fun 2021 where he took a small display space for the “Voodoo Jet”. It’s a super light version of a Long EZ, and the carbon fiber parts looked well-made. Expected empty weight with the targeted Dutch jet engine was 475 lbs – I thought he...
  9. P

    Bad battery... or ???

    Two years ago I had a chance to test crimps made with a retail hydraulic crimper. I made battery cables and one of the lug ends had too small a hole, so I had to replace it. That was a chance to cut into the lug and check how my squeezing was doing. Below are cross sections of the same cable...
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    Body filler.

    "There was one rust-brown colored filler material they made which yielded some very useful properties." I think this is a reference to wood powder. My experience says it is decent thickener (not as good as silica) and has decent strength (not as good as flox). It is hard to sand (better to...
  11. P

    homebuilt parking at Sun n Fun

    Weather? Sure. But also access to the vendors. Last year at SnF I had my Wicks and B&C orders handled by the heads of those companies. Whelan? you end up talking to the head of sales. Levil? the founder. And it goes on and on like that. After years of good intentions they are finally...
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    Complete system for day VFR but under class B

    I'm hearing about use of the Levil BOM as the b/u instrumentation in IFR aircraft. I don't know that it would be appropriate as a primary, but it sure does a lot for very little spend and an easy install. Levil Aviation Broadcasting Outer Module (BOM)
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    Mixing different epoxies

    My understanding is that your hardener is specific to your resin - don't mix across those. Further, I understand that an individual part can benefit from a mix-and-match of of specialty epoxies . So the inner face of my cowl is a fuel resistant epoxy (I use Max GRE), then a CF layer with...
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    Aircraft Ash

    We built the EAA's Bleriot replica using ash - I was on the team steaming strips and worrying about wing tip bows. On the one hand, it's the most memorable OshKosh ever. On the other hand, too darn heavy to fly.
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    Composite Cowling

    Make sure to use the core intended for epoxy resins (not polyester!). For my cowl I'm following this guide: CoreMat cowl 2.pptx Since I'm not at OSH, I'll aim to have a good weekend on the project. Build on... PK
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    Friday night Cozy builder's zoom call

    Sam Tilleman, president of Saber Manufacturing – Friday night interview on the Cozy Builder’s call. Join us at 7 pm CDT at Join our Cloud HD Video Meeting We argue the relative performance of 2 vs 3 blades and Catto vs. Hertzler / Persson, but we all use the Saber extension. Why is that? On...
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