Creating a new fuselage access hatch - replacing Old Curlycue

Well, by this time, you have seen the work to replace the instrument panel, now it's time to replace that old hat self-access cover.

Just like the instrument panel, this cover was so full of holes, that it was warped and curling outward.





I used the same process as I used in making the instrument panel

The process included using a flat board that was sealed and waxed to prevent the resin from adhering to the surface.

I used Peel Ply, E-120, two layers of carbon fiber, followed by a layer of 7725 and then covered with Peel Ply.



I used the same curing process of a 24 hour pre-cure at 75 degrees, followed by a post cure of 15 hours.



I drew an outline using the old cover.


With the outline completed, I cut the excess off, and carefully sanded the material until I had a working shape.










I had a slight problem removing the glass sheet from the form, and thus there is a blemish that can be seen as a light blotch near the bottom of the hatch. Since this is the painted side, There is no problem with the blemish being there.
I used a Dremel with a grinding head to cut the notches and latch lever guide hole. I etched a circle for the cockpit vent, but I had not decided on cutting it out just yet.



The test fit on the fuselage.






Here is a photo of the old cover with the replacement.

I have the new piano hinge too, but we will need to test to see if the rivets will hold in the carbon fiber cover.





So much more to do...