Photo 1: Gear mounts are ready for assembly. 1" sections of 1/8" dia. dowel will be epoxied through the small holes in the plate, helping to anchor the plate to the core, and distribute the gear loads deep into the core. The back sides of the blind nuts are covered with masking tape to prevent the threads from filling with epoxy.

Photo 2: The gear mounts are glued in place with 30 minute epoxy and some microballons, not thick like you would use to make a fillet, but just enough to fill any irregularities and not run out of the joint. The dowel holes are filled with 30 minute epoxy using a plastic glue syringe, then the dowels are coated with epoxy and pushed into place, the ends flush with the surface of the gear plate. After the epoxy cured, the foam was cut out using the method described in my last post.

Photo 3: The Spring-Air main gear in position.