rand robinson
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The KR2S Project

Forward Deck
As with most things I build on the KR, I have an idea of what the forward deck will be like in the end, but how I get there tends to be based on techniques and procedures learned by those who have built before me, occasionally mixed with some of my own improvisation.  All I know is that my forward deck is going to be made of carbon fiber.  How it exactly hinges, latches and fits the longerons is something that I will confirm as it begins to take shape.
 
template The paper templates were customized from those available for download on Mark Langford's web site.  I imported the drawings into AutoCAD and then manipulated them to fit my firewall and cockpit dimensions exactly.  By exactly I mean that I reprinted the cockpit template because it was 2mm too short in width.
These were then stuck to 12mm chipboard and then cut out with a jigsaw.
jamb foam The templates become the front and rear outlines of the forward deck when timber sides are added to create a jig and then the foam is added.
underside of deck The foam doesn't need to be 100% free of blemishes as long as those blemishes will be sanded out during the shaping.
 
stick foam Expanding foam was used lightly to hold the urethane in place enough to sand the other side.  I was careful to not get the expanding foam into the joins as it creeps through and makes a smooth sanded urethane surface almost impossible.
surform sanding I used the surform to shave the majority of foam to the templates, finishing off with a long sand paper straight edge.
slurry and plastic A coat of slurry and then the marker on the plastic shows where the wetted out piece of carbon fiber will extend 1" beyond the deck shape.
forward deck carbon fiber The inside deck has worked really well.  Perfectly smooth and even in texture as I take the time to ensure the peel ply is not allowed to be dry in any area.  I do this by applying pressure and massaging the resin through the dry areas with my fingers.
separate jig Grey tape was added to the template edges as a release for the resin.  It works really well when separating it from the foam though the expanding foam needs to be cut free with a razor blade first.
upturned deck Here is what the forward deck looks like when out of the jig.  It is surprisingly rigid even with only one side covered with CF.
firewall template The original templates had a 3/8" offset added to the inside to line up the underside profile.  The top profiles have been cut out and stuck to chipboard
clamp templates This chipboard is then clamped to either end of the previously molded deck to provide the sanding profile for the upper surface.
straight edge sanding A little time spent with the surform and the straight edge and the top of the deck takes shape.
gaffer tape Tape and plastic is applied to all areas that I don't want the resin to stick to.  This includes the sides of the KR2S and templates.
packing This is the area where the filler block sits level with the edge of the top longeron.  As the deck goes to the edge of the 2.5mm plywood, there is a 2.5mm gap between the filler block and the edge of the deck.  This area has been filled with a piece of sanded urethane.
peeling plastic The plastic sheet is peeled off the carbon fiber and fiber glass while it is still wet, at which stage everything is squeegeed against the foam.
forward deck staples The peel ply is held taught with staples and everything is allowed to cure over night.