January 26, 2008 - Big Day
I worked on the project ten hours today, which is the most I've ever done in a single day.  I started the day with the vertical stab nutplates for the emp fairing.  I drilled the holes out to #27 (for the #6 screws) and drilled the nutplate rivet holes.
 
My friend Bill B. is considering building an RV and asked if he could help out with the project.  I put him right to work installing the nutplates in the VS and HS.  Looks like he's enjoying himself -- I think we might have a future RV builder here! 
 
I realized the vertical stab tip needed a foam insert so I cut one to size and epoxied it in. 
 
I pop-riveted the top tip on the rudder.
 

In my previous work with the lower emp fairing, I felt like I was getting nowhere.  So I decided on a different tack.  I decided to fit the fairing to the fuse first.  Later I will trim the top to nestle against the Horizontal stab bottom.  I think I'm going to go with the rubber channel, although it is optional. 

I drilled out the rivets in the F-709 bulkhead, then clecoed the fairing to it.  I duct-taped the fairing aft end to the fuse.  I then realized that the pre-drilled fairing holes should match the longeron rivet holes.  I feel like I'm on the right track now with the lower fairings.
 
After Bill finished with the nutplates, I had him widen the eyeball hole in the firewall.  We used the Unibit first to open the hole to 3/4", then then dremel tool to take it out to 1 inch.  It's a pain, though.  I wish I had just invested in a punch. 
 
I decided it was time to do my first fiberglass work.  I had found the below buide to fiberglass on the web and used it as my guide.
 
I had previously acquired all the below materials that the guide said was required:  West Systems epoxy, fiberglass cloth, micro balloons, cotton flux, plastic drop cloth, rotary cutter, peel ply, squeegee and rubber gloves.
 
I followed the seven steps exactly and although messy, it worked pretty well.  I reinforced the foam in the tips with glass, per the instructions. 
 
I mixed the left-over epoxy with microballoons and poured it on top of the foam. 
 
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