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Dave Wilenius' Cozy Mark IV Project

Dave Wilenius Cozy Mark IV

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Dave Wilenius' Cozy Mark IV Project | wilenius.webcentre.ca Reviews
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Dave Wilenius Cozy Mark IV
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Dave Wilenius' Cozy Mark IV Project | wilenius.webcentre.ca Reviews

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Dave Wilenius Cozy Mark IV

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1

Dave's Cozy Mk IV - Chapter 14

http://wilenius.webcentre.ca/chap14.htm

Chapter 14: Main Spar. In Chapter 14 you build, as you might have guessed, the main spar. The main spar joins the fuselage and main wings together. The main spar also acts as the aft border of the strakes. From reading the email archives, other builders web pages, and my own experience, the keys to successfully completing your main spar are:. Get some help glassing the interior and/or consider breaking the glassing into multiple stages - I did both (the 2nd time around! Precut your spar cap tape. This st...

2

Dave's Cozy Mk IV - Chapter 10

http://wilenius.webcentre.ca/chap10.htm

The goal of Chapter 10 is to have a canard, minus the elevators. The highlights are cutting form cores, installing a shearweb, installing spar caps, and glassing the top and bottom skins. I read that you should get "angel hair" but since I hadn't done this before wasn't sure what to expect. Just so you know what it should look like I've included a shot, below. We finished cutting all the cores including cutting the troughs as seen below - next step drawing the center line on the cores. Next I dremel rout...

3

Dave's Cozy Mk IV - Chapter 7

http://wilenius.webcentre.ca/chap7.htm

Chapter 7: Fuselage Exterior. Making those little aluminum inserts for the gear cover attachments was a real pain. Even aluminum generates heat when cut so I had to go slow. I cut strips 1/4" wide and then cut them to length with the dremel. Treated them with alodine and then floxed them in. When glassing the scoop I cut darts at the corners to allow the glass to wrap around properly onto the firewall. After that you're ready to tackle shaping the bottom. I looked at Oreste Mucilli's website. Here I am s...

4

Dave's Cozy Mk IV - Chapter 5

http://wilenius.webcentre.ca/chap5.htm

Chapter 5: Fuselage Sides. I read with amusement Marc Zeitlin's Oaf stories and I've got one of my own. As background I generally work on the plane in the evenings after work and one day out of the weekend. While doing the sides I was particularly excited and raring to go! Morale of the story is don't assume brain is active between 1am and 9am. Just as Nat suggests not starting large layups late in the day, it's probably unwise to be measuring, using new tools, or using new techniques late at night.

5

Dave's Cozy Mk IV - Chapter 6

http://wilenius.webcentre.ca/chap6.htm

Chapter 6: Fuselage Assembly. This is an exciting time in the building process because you get to start bonding multiple pieces together to make a bigger piece. It is here you learn the art of BID taping. I discovered the similarity between composite and tube and rag construction techniques. In reality the Cozy is a frame constructed of 2" wide BID tapes separated by panels of fiberglass covered foam. These things connect everything to everything else. Here's the other end, F22 firmly held in place.

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