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The glare shield, which supports the instrument panel and covers the avionics, had to be made from scratch. Using foam and body fillers, Tim sands and shapes the plug for the mold. |
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More sanding... |
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The plug is removed from the plane. Supports are added and final body work is done to the plug in preparation for making the fiberglass mold. |
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After treating the plug with a release agent, gel coat is applied... |
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then several layers of fiberglass while the gel coat is still wet. This is allowed to cure overnight. |
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The finished mold removed from the plug. |
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Fiberglass and a foam inner core is laid into the mold. The part is immediately vacuum-bagged to remove excess resin. |
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The glare shield is removed from the mold after curing and fitted to the plane. |
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More fitting...with the instrument panel installed. |
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When the glare shield fits, final bodywork and primer are applied. |
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Tim is painting the glare shield. |
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The finished product ready for final installation. |
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The glare shield installed in the plane. |
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