Sanding the plug of the cabin

Besides optimizing the control mixer and working on a second prototype for load testing, I’ve been working sporadically on the plug of the cabin. The rough shape is there, but many necessary and essential steps follow.

The video on making a molded fuselage by The Arnold Company  is very inspiring and shows very well how much work there is behind a good plug:

I follow essentially the same steps, but decided to cover the surface with veener instead of glass fabrics. It’s going to be the same procedure as last time for the center section’s plug. The reason is that veneer smoothens somewhat and filling the surface should be easier. Enough abachi veneer is ordered and should arrive soon.

Before covering with veneer, the XPS core needs to be sanded. Finishing a plug is a multiscale process, in the sense that you start with a rough shape and in each following step you increase the quality of shape and surface. At the current step it’s not about achieving the best surface quality, but rather about getting the right shape without kinks in curvature. Surface quality is achieved later by sanding the veneer and filling.


This picture remebers me to Ed Sheeran’s song Shape of You:

„Girl, you know I want your love
Your love was handmade for somebody like me
Come on now, follow my lead
I may be crazy, don’t mind me
Say, boy, let’s not talk too much
Grab on my waist and put that body on me
Come on now, follow my lead
Come, come on now, follow my lead

I’m in love with the shape of you
We push and pull like a magnet do
Although my heart is falling too
I’m in love with your body…“





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