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Welcome to the Cozy Midnight website. I'll be documenting the construction of my experimental airplane called the Cozy Mark IV. Over the last four years, I've dreamed, thought, planned, prayed, and hoped of building a Cozy MkIV. Finally we're in a position to start. So let the journey begin...
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FAQ
About my Cozy.
Daily Logs
Daily tasks completed & hours.
Chapters (On Left) Detailed notes and photographs by chapter.
Shop Cam
Watch me build my Cozy.
Links
Websites I find useful. Add your favorite website, click
Add a Link.
Media Gallery
Photographs from various events. Some personal photographs.
E-mail
Send me an email.
Chapter 6 is done and well into chapter 7. I'm in the process of shaping the NACA inlet. The web page is still few weeks behind. I'll get it up to date the next time I'm out traveling and can't be building.
Work will be very sporadic until October. From July 28 to August 22, I'll be away either on work or vacation. Then every third week I'll be out traveling for work.
Leveling Foam with a Router
Friday, July 11 2008 @ 05:47 AM Eastern Daylight Time
Contributed by: Drew Chaplin
The NACA inlet is constructed out of urethane foam. The stuff is difficult to sand. Not because is hard to sand, but because it sand so easily. If you look at it cross-eyed, then you can dent it. I was concerned that if I hand sanded it level that I would be satisfied. I could anticipate having a ding here or there, or not having good transitions through the the microed area.
I picked this idea up from Craig Kossowski (ChasingMars). Look under chapter 7, NACA Scoop. Craig built a very nice jig, but I wanted something a little simpler. I like using routers and this little jig only cost about $8 to build. It probably not any faster than the plans methods, but I'm pretty sure it was easier. I would definitely do this again, but next time I'd use a different type of foam for the NACA construction. Urethane is good for hand sanding a shape, but in this case we are after a flat surface. It made since to be to machine the surface flat.
I have nothing against the plans methods; it has probably be used by 99 percent of the planes built. I'm a huge fan of jigs and fixtures when they're appropriate. A good jig will just make a part easier to build.
So here's my most recent video addition on using a Router to level foam. I've ruthlessly edited to make it as short as possible. I think I've done it. It is 4 minutes long and about 10 megs.
....and yes I do realize I said a 3/4" diameter bit when I was holding a 1/2" bits. Ooops
