Next step is to build a simple wooden frame so the glassed core of only two plies holds the shape of the fuselage. This is the same technique that is used to make the fuselage bottom so for once was easy to understand.

I used a lot of 5 minute glue as this can be carefully removed later and I knew this was going to be fun getting the brake core off and didn’t want a failure in the contact with the shape jig.This bond needed to be stronger than any force I’d need getting the whole assemble off the bottom of the fuselage.

I screwed on some longer timber pieces to get a better moment arm to remove the brake. Gluing the core was a balance of too little glue or too much. I used too little initially and had to add 5 mt glue all around the edges before I glassed the outside of the brake. Of course this was going to make it fun later (which is now).

Once there was a bit of movement with the hammering I kept wiggling and eventually the brake core came off with only a bit of core dug out in clumps. The brake area has to be deepened later and the edges get a joggle as well. This step is all about the shape of the brake on the fuselage. The rest is repairable and not so critical. OK its not pretty right now. I’ll concede that.

Frame to hold the brake shape

Extend frame for removal

Leftover dings