Cabin Construction
May 2001, I changed the front motor mounting system to aluminum instead of wood. Click here to see the outcome.
The pictures should be showing up now. 6/26/01
I did not build the top part according to plans. I used Styrofoam in the front section around the lift duct to provide for easy forming.
Items to note in this picture are the Styrofoam sides and foam wrapped around the lift duct.
My theory was threefold:
- was the impact resistance of the foam if the fan came lose.
- was the sound should be less.
- easy forming for a more rounded aerodynamic shape.
I ended up not following the sketches you see on the foam.
In the spring of 2001 I rebuilt the front motor mounts. They are made of 1" aluminum square tubing. I will try to get updated pictures of the changes I made.
The tool on the foam is a carpenter's rasp. It is the best tool I have found to shape Styrofoam in a hurry. I then use another sanding tool I made, it is made with a 2x4 about 12" long and 2 pieces of 1/4 sheet 40 grit sandpaper with a self stick baking on it. You most commonly use them on a palm sander. This tool works excellent for finish sanding. You can use this self stick sandpaper on any size piece of wood or aluminum to create excellent sanding tools to get to every nook and cranny.
I used 3 strips of 1/4" x 3/4" strips to create the proper bend. Using full 3/4" dimension wood did not work. I used this method all over the craft when I needed to bend something that did not like to bend.
The plans are not real clear on how to finish the dash. You kind of have to wing it at this point. You just have to ensure room for the stick, gauges, leg room, access to wiring underneath, etc. After learning how to work with these materials and hovering for a year, I decided how I wanted my dash to look. Pictures of the change coming soon.
I would not recommend this type of dash. I built a new design.
I used a bent piece of 1/8" ply for my dash. This put the keys and gauges up a little higher and left room so the stick would not hit the dash. I redesigned it after the first season. I will try to get pictures up of this change. The basic structure of the cabin and dash does not change very much.
