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Old 03-30-2005 | 11:56 PM
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flyintexan
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From: tomball, TX
Default RE: Insight build...another wood roach.

It was time to cut and fit the top, forward fusebox sheet which is made from a single piece of 1/16" ply. This top piece will tie in all the forward fuse formers and the back of the firewall. As you can see, it starts as a 6" wide x 30" long sheet. I start by fitting the sheet to the back of the firewall which has the right thrust built in. Once I get a good fit there, I cut the other end to length so that it ends where the rear top fusebox sheeting starts. As you can see (barely) in the second pic, all the lightening holes are laid out in pencil. Then I proceed to waste approx. 90% with the scroll saw. I glue on what's left with minimal amounts of epoxy. I also add a 1/8"lite ply firewall brace midway between the top and bottom of the fusebox (glued in with epoxy). With this in place, the 1/8" lite ply firewall is now plenty rigid....in my opinion.
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