This was an ‘exciting’ layup. Somehow three plys of BID from flat pieces goes in that cavity.

I micro slurried the blue foam and then mixed a really thick batch and did the edges to help the glass to flow better. There were a couple of minor dings and they got the stiff micro as well.

I then make a ‘flox ring’ around the aileron rod hole. I have this idea to dig a ring almost to the hole edges and fill it will a little flox. This will reinforce the hole like a flox corner.

The first two pics detail the shape, lots of fun getting BID to sit way inside that. I made very oversized pices and taped it to the top outside with the cloth just draping. Then I secured the back wall and wetted that out with a roller. I then started a rough trim of the cloth and made it sit in the corners. The hardest part is right at the top, getting it to sit upside down, trim the cloth and keep it all smooth with no wrinkles in the corners. It mainly working with gloved hands and fingers.

The last shot shows clamps and I used some mixing sticks with tape on them just to be sure the edges stayed put while it cured. It was a good result!

A serious shape for the BID

Bent BID works

Sticks and clamps for the edges