L3 Page 3

Construction Begins 2-22-04 It's really not warm enough yet to begin major work, but warm enough that some of the work can at least start. Step1 - Begin nose cone assembly. Nothing out of the ordinary planed here. To add strength and allow the bulkhead to be removed so I can add weight if needed I will epoxy a 3/8 inch threaded rod into the nosecone. The Amraam's nosecone will actually consist of the following parts, the 7.5 inch fiberglass nosecone, a short section of 7.5 glassed tubing, a coupler, and bulkplate. I will pour around 4 inches of epoxy into the tip to anchor the rod. After allowing the epoxy to fully cure I will add 2 part expanding foam to fill the cone about half way, leaving space in which to add weight if needed. My trusty Dremel and sanding drum were first used to get inside the nose cone and "rough up" the insides to make certain the epoxy and foam will have something to bite into. No prep work was done to the short piece of airframe since it will be removed once the epoxy cures; it, along with the bulkplate are at this point only to insure the rod is properly centered in the nosecone. Also note the coupler is not yet installed, again this will be prepared later in the construction process.
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7.5 inch bulkplate
First step was to drill a 3/8 inch hole in the center to allow the 3/8 inch threaded rod to pass through. |
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Threaded rod and bulkplate
If you look closely you can see the bolt and washer on the far left of the rod. This is to give the epoxy some extra surface to grab onto. To the right of the bolt is a coupler since I needed to add two sections of rod together. |
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Rod in nosecone
Here's a look before the epoxy pour. |
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Ready to pour
The rod will be anchored to the tip of the nosecone with West System epoxy (resin + fast hardener + 404 high density filler) |
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First pour done
After the first pour (about four inches worth) the bulkplate is loosely attached to keep the rod centered during the cure. |
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Rod and Plate
Here's a better view, showing the three screws (temporary) added to insure I can pull the plate back out |
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Rod and Plate
Last look before leaving overnight to cure. |
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