With my flexible ferry tank going in the back I need to cover all the sharp edges so it sits well.

I wanted a cover for the air-brake anyway as the little air gap in the floor needed sealing. I started out thinking I only required a simple 2 ply glass cover. Now I realize I need quite a strong cover that will also be a part of a foot rest for the GIB and a place for additional avionics AND be able to take all the weight from the ferry fuel without crushing.

Suddenly I needed quite a strong cover and a certain shape too. What you see in pic 2 is my solution, I hope. I’m leaving the edges square too as other things will fit to the sides. The curve is such that the tank pressing on it should press evenly.

I’ll find out for sure when I fill up with 250lts of fuel and either do or do not hear cracking sounds! I do know that if I leave it uncovered I risk problems with using the landing brake.

Just to see if I could do better work I hard shelled the blue foam with West system and thick micro. This I have with a fast cure hardener. Although its hard to see in pic 3, after hard shelling with peel ply I had a great surface to layup the glass onto. Each of the three sides I then had to do in separate layups. I still have inside work to do once the outside is sorted.

Fitted foam block

Close to the right shape

Lots of layups