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From: Mark Sletten <mwsletten@gmail.com>
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Subject: Re: [LML] IV-P Interior Finishing
X-Original-To: Lancair Mailing List <lml@lancaironline.net>
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Mold chicken wire to the shape you want, then paper mache over it for
rigidity? You can get a fairy smooth finish with paper machce.

A hot wire is a great way to cut foam. Maybe shape the wire to the desired
plug shape and cut the foam with it?

--Mark


On Wed, Jun 18, 2014 at 6:15 PM, Robert R Pastusek <rpastusek@htii.com>
wrote:

> Lancair Builders,
>
> I have a task that's been troubling me for several years now...at least
> I'm claiming this as the reason for flying, rather than finishing the
> interior of my airplane!
>
> I am trying to make a "plug" in the shape of the front and back edges of
> the door frame/fuselage intersection. My intention is to use this to make a
> fiberglass molding that I can cover with headliner material like I plan for
> the rest of the fuselage inside top. I have tried to "carve" hard Styrofoam
> into a shape that will fit the door frame, but it's a three-dimensional
> curve, and I was not able to produce a satisfactory part from solid foam. I
> then  tried to use some "weather sealant" spray foam, after taping over the
> subject area. This was a TOTAL MESS--spray everywhere except where I wanted
> it. The foam that actually got near the right location dripped off before
> it became rigid. I have tried modeling clay...way too much required, and
> too difficult to work with...etc...etc...
>
> Any ideas most appreciated on a way ahead...
>
> Thanks in advance.
>
> Bob
>
> --
> For archives and unsub
> http://mail.lancaironline.net:81/lists/lml/List.html
>

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<div dir=3D"ltr">Mold chicken wire to the shape you want, then paper mache =
over it for rigidity? You can get a fairy smooth finish with paper machce.<=
div><br></div><div>A hot wire is a great way to cut foam. Maybe shape the w=
ire to the desired plug shape and cut the foam with it?</div>

<div><br></div><div>--Mark</div></div><div class=3D"gmail_extra"><br><br><d=
iv class=3D"gmail_quote">On Wed, Jun 18, 2014 at 6:15 PM, Robert R Pastusek=
 <span dir=3D"ltr">&lt;<a href=3D"mailto:rpastusek@htii.com" target=3D"_bla=
nk">rpastusek@htii.com</a>&gt;</span> wrote:<br>

<blockquote class=3D"gmail_quote" style=3D"margin:0 0 0 .8ex;border-left:1p=
x #ccc solid;padding-left:1ex">Lancair Builders,<br>
<br>
I have a task that&#39;s been troubling me for several years now...at least=
 I&#39;m claiming this as the reason for flying, rather than finishing the =
interior of my airplane!<br>
<br>
I am trying to make a &quot;plug&quot; in the shape of the front and back e=
dges of the door frame/fuselage intersection. My intention is to use this t=
o make a fiberglass molding that I can cover with headliner material like I=
 plan for the rest of the fuselage inside top. I have tried to &quot;carve&=
quot; hard Styrofoam into a shape that will fit the door frame, but it&#39;=
s a three-dimensional curve, and I was not able to produce a satisfactory p=
art from solid foam. I then =C2=A0tried to use some &quot;weather sealant&q=
uot; spray foam, after taping over the subject area. This was a TOTAL MESS-=
-spray everywhere except where I wanted it. The foam that actually got near=
 the right location dripped off before it became rigid. I have tried modeli=
ng clay...way too much required, and too difficult to work with...etc...etc=
...<br>


<br>
Any ideas most appreciated on a way ahead...<br>
<br>
Thanks in advance.<br>
<br>
Bob<br>
<br>
--<br>
For archives and unsub <a href=3D"http://mail.lancaironline.net:81/lists/lm=
l/List.html" target=3D"_blank">http://mail.lancaironline.net:81/lists/lml/L=
ist.html</a><br>
</blockquote></div><br></div>

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