Science

Overhead Console/Beams

Overhead Console

Cut the overhead console to the length you need. Mark the locations of the fresh air vents and the reading lights. Cut the holes for the air vents and the lights. Seal the ends of the console with 2 bid. Mark the sides of the console when in place. Create a 1" flange on the roof on the inside of these lines and rivet in place. Glass and rivet the console onto the flange. Sand, prime and paint. Drill screw holes for the vents and the lights and install. Wire the lights to the rear buss. Wire a light switch from the main panel to the rear buss.   

Beams

I think the carbon pattern in the beams is way to beautiful to cover up with paint so I decided to finish them with a red candy apple. I made a mistake using spray can paint. Do not use Spray Can Paint!!! The beams are porous. When not sealed with a catalyzed material the gases escape from the beams when warm and will make large ugly zit like bubbles. I know this. I refinished the beams 4 times. That is over 40 hours and $100 of paint. Seal the beam with 3 coats of Velocipoxy. This is clear and will seal off the pin holes. If you like the natural carbon color wet sand with 320 grit. Coat with clear. For candy apple wet sand the clear coat after cured with 400 grit. Paint with candy apple. Clear coat when it gets tacky. Good Luck.

 

Seats

Seat Rails

Only the front seats came with rails. I wanted the passagers to enjoy the freedom of adjusting their seat so I built rails for the back seats. Using the front seat rails a as a pattern I cut the tubing and strap metal to length.  Weld the parts together. Drill the adjustment holes through the lever and the left slide rail for the left passenger seat and the right rail for the right passenger seat. Attach a 3/16" machine screw in the lever for the adjustment pin. Sand, prime and paint.

Seat Assembly

Place the seat hinges along the bottom seat and drill two bolt holes through the hinge into the seat hard point. Tap the hard point with 10/32" tap. Attach the hinge. Repeat on all seats. Set the upper seat in place. Drill two holes through the hinges and into the hard point. Tap with 10/32" tap and install screws.

 

 

Seat Installation

 Install the rails to the seats. Place the rail on the bottom of the seat. drill mounting holes from the rail into the seat. Bolt the rails onto the seat. Mark the location of the seat rail on the seat hard point on the floor of the fuselage. Drill bolt hlose through the rails into the hard points. Thread the hard point whith a 1/4" tap. Mount the seats.

Upholstery

Sound Proofing

To eliminate as much engine noise as possible I used 1/2" closed cell foam as the pading for the upholstery. The foam is  blue camping pad found at any sporting goods store. Important!!!  Use a high quality, high temperature adhesive to glue the cloth on the foam or it will come apart in hot conditions. Do not use a hoby spray adhesive.

Make a pattern for each section of the interior out of paper. Trace the pattern on the foam. Cut the pattern out and trim to fit.  Spray both the foam and the back of the cloth and wait 1 minute till it gets tacky then lay the cloth on the foam and smooth out.  Put the piece in place and make the next pattern and repeat till it is finished. I padded the headliner as well as the divider and the floor.

Divider

Make a pattern for the three pieces of the divider out of cardboard. Trace the pattern on a piece of 1/8" panel board. Cut the bottom panel out trim ti fit with 1/4" clearance around all edges and sand.  Repeat for each panel. Create mounting brackets with 3/4" angle aluminum and rivet in place.  Trace the panel onto the foam. Spray the panel and the foam and glue. Cut an over sized piece of cloth. Spray the foam and the cloth. lay the cloth on the foam and smooth out the cloth. Flip the panel over and spray the edges and the cloth edges and glue in place. Staple the back edge.

 

Front Panel

This is the most difficult part. There are so many shapes and contures it mkeks it necessary to create two separate pieces for the pilot side front panel. Make a patern out of paper for the inner brake panel. Make sure it overlaps one inch onto the outer panel. Trace and cut the cloth. Lay in place and mark the brake rod holes. Cut the holes. Glue in place. Make a pattern for the outer panel. Cut out of cloth. Glue in place over lapping onto the inner panel.