All, Some time ago there was a discussion about gluing pieces of foam together to make a larger block that can then be sanded. For years I used the biggest blocks I could find and used spots of five minute epoxy to join them together. Then just hoped I didn't hit a glue spot. It worked but only because I couldn't figure out a better way of doing it.
In the last issue of Kitplanes there is an article on doing this with Gorilla Glue and Sherwin Williams Shrink Free Spackle. I am starting on my new bottom cowl this weekend and really needed something like this. I did a quick test and will say that it works wonderfully. But for whatever reason they didn't show a photo of the materials. There are multiple kinds of Gorilla glue and I didn't know how many types of spackle there was so I have attached a photo of what I used and as I said it worked great. The glue came in a 4 oz round bottle, is brown, and is labled as "original". The spackle comes in several sizes from half pint, pint, quart and gallon. You mix approximately twice as much glue to the spackle. I did not measure it I went with close enough. I mixed it for a few seconds in a paper 3 oz Dixie drinking cup until it reached a consistent color and spread it where I wanted it. Apply your clamping force and let it cure. The cure is based on temperature but a few hours in the low 60's was enough for me. The mixture will expand a little so if you are trying to fill a void it will do that. I would not say that it was excessive or forceful. After cure I couldn't separate the foam without destroying it. The seam cut, sanded, and filed just as if it wasn't there. I did not hot wire it but would expect that to work too. Stephen Teate Paradise, Texas The information in this email is confidential and may be legally privileged. If you are not an intended recipient, you should delete this message. Access to this email by anyone else is unauthorized, and any disclosure, copying, distribution or action taken or omitted in reliance on it is prohibited and may be unlawful.
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