Bob,

I used the foam that florists use in vases to hold fake flowers in place.  Rigid but easy to carve with coarse sandpaper.  Careful not to put your fingers through it.  In some places around the door I simple glassed over it and left it there.

Pete


-----Original Message-----
From: Robert R Pastusek [mailto:rpastusek@htii.com] Sent: Wednesday, June 18, 2014 4:15 PM
Subject: IV-P Interior Finishing

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