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Create stencils
Using 3mm MDF mark out, cut and sand to shape.
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Accuracy all important
A router was used for the round edges. It took longer to make the stencil than the actual parts.
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Recycle
Off cuts can be easily marked and used. |
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Sanding.
All pieces both (12mm and 24mm) are clamped together and sanded to maintain consistency. |
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More sanding ...
Yeap about 60% of the time is spent sanding. |
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Assemble pieces.
Check all dimensions before drilling.
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Drill.
Pre-drill and counter sink all holes. Then glue and fasten using wood screws.
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Check dimensions.
Check again to ensure dimensions are maintained before the glue sets.
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Route middle section.
Due to the weight of MDF route unnecessary material.
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Top side view. |
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Support for seat.
Ensuring the cockpit tub is hollow as possible.Support legs are added for the seat floor.
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Seat bottom.
Placing seat in the sun and with the aid of clamps I was able to shape the seat bottom by wetting small areas. It took about three hours.
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Angle bracket.
Three days of frustration finally solved after purchasing a sheet of Polypropylene plastic.
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Gluing was not recommended so an aluminium angle bracket (shown in the previous picture) was used to enable the plastic to be riveted. |
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The material just falls into place and keeps it's shape when riveted down.
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