Another entry for Tony's contest...
An electric router of the type used for woodworking is ideal for making the
rebates for the W18 plates. Took about 10 minutes to get the depth set by
trial and error on scrap foam, then about 20 minutes to make all rebates for
both wings. Of course, you have to sand the edges by hand to make a smooth
transition.
The router is also useful in setting the rebate depth in the foam around the
edge of the aileron bellcrank access window once the top glass is removed.
And if the router depth is set much deeper, the hole through the center of
the access window can then be roughed out including foam and the lower layer
of glass. A Dremel with a sanding drum is the easiest way to do the final
adjustment of this hole's bottom edge, then use the Dremel wire brush to
remove a little foam for the flox corners.
One drawback to using the router is that it turns foam and/or fiberglass to
powder. The dust is as hazardous as that produced by sanding these materials,
so use appropriate safeguards.
Regards,
John, #A044
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