Bonding First Plug

The first fuselage plug is now all bonded (glued) together. The first two blocks of foam were levelled to within a hundredth of an inch – less than the thickness of a piece of paper. This makes a perfectly flat foundation for the other blocks. This is also the centreline of the fuselage so getting this line straight is necessary so that the other parts of the aircraft will fit and it will fly straight.

The other blocks were then aligned onto the first pair, using alignment rods and careful measuring before the epoxy resin was poured.

The next step is to fill in the holes from the alignment rods, since they will never be used again, and sand the surface to smooth out the grooves made by the CNC machine. It won’t be long until we start laying up carbon fibre onto the plug.

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