Building a New Rear Bulkhead Cover for my Cozy MKIV Airplane

In this video, I build a replacement bulkhead cover for my Cozy MKIV airplane, using fiberglass and foam.

0:00 Intro
0:12 The Old Cover
0:43 The New Parts
1:05 Building The New Cover
2:05 After Cure Results
2:51 Sanding and Finishing
3:25 Finishing Complete
3:41 First Test Fit
4:46 Second Test Fit
5:33 Final Fit

No content in this video should be taken as flight instruction or advice. Refer to your aircraft POH and consult your CFI. This video has been edited for time and content, and context may be lost or distorted. This video is for entertainment purposes only.

#Canard #Cozy #Bulkhead

[flysport_tedder]

watching you makes me really want to do some glass work.

[billwilliams]

Mike, you gonna the best Cozy ever. Congrats on your work.

[Verb]

Nice work. It's not structural, so you really only needed one ply of BID per side, and if at all possible, try to use peel-ply on all your surfaces. Saves so much sanding.
Cheest.

[Stephen_Heathcote]

Excellent. Nice work, looks tidy now 👍

[russopland]

Hey Scott. Really enjoying following along. Your attention to detail and diligence are admirable! Quick question on this one: is there any heat buildup back there or is there adequate ventilation?

[dwightherkness]

Really amazing fiberglass work, do you ever do vacuum bagging process

[russellesimonetta]

Yeah, not structural so bubbles and or dry spots are nothing. Maybe some Velcro tabs to keep it from migrating around back there. Oh and some foam head rests made from foam and sign board covered and Velcro on would be a nice touch. Good work. Did you make any head way on you cooling issues??

[TRabbit]

Mylar would be a much better splash guard for your table than paper. Epoxy won’t stick to Mylar…. [ed] Notice the waviness of the fibers? Those fibers should be straight as an arrow in the required direction for strength. This isn’t a structural piece so it doesn’t really matter beyond aesthetics, but practice makes automatic. Tugging on either end of the fabric along a set of fibers you want to straighten works great. Also, once laid down onto the piece, wetted out, and squeegeed, trim the fabric to within a half inch or so to keep the fabric from lifting up from the core around edges. Peal-ply works really well to create a nice finish for additional bonding or paint, requiring minimal to no sanding to prep for such a step. Be sure to leave it on until you are ready for that next step, or the oxidation layer will form quickly and you’re back to having to sand again.

The end result of your bulkhead cover looks fabulous anyway! So take this all as merely suggestions for experimentation later.

[stevesomers]

Scott, nice job, looks great! Say, did you solve the cylinder temperature issue? I suspected that you had air stagnation around the cylinders and that perhaps your exit port was not low enough pressure to allow the engine to breath. I hope it's resolved. Cheers!

[johnjagels]

Scott, just curious, as meticulous as you are with the repairs did you weigh your plane BEFORE you initiated the process? I'd be interested to know with all that you've done if the gross weight has changed/ CG perhaps?

[zeitlinm]

Before putting anyone in the rear seats you need to cut slots in the bottom of the new cover so that the shoulder harnesses can come straight off of the attach points and not have to wind their way below the cover. Not safe for the rear seaters as is.

[ianhart]

Too much work... not enough flying! (feeling your pain)