Stearman build

You have created alignment with the bar through the middle, can’t you just bolt the two halves together, no separator required, or have I missed something?

Good to know you are back on the Stearman project, we have missed it. Gives me enthusiasm to get back on my Vampire project which has been neglected for so long that people (other than Simon Dean) have even given up asking me how it’s going!

Regards,
David

This is my plan in brief but not going into detail how i plan to make the moulds or use them to lay up the actual cowl.

I'm currently at stage 1 in attached pic but i need to fill sand polish the shape to a high standard to form perfectly mating front and rear moulds - as pic 2

but in order to produce the two halves with accurate square edges at the mid point join i need to be able to have a separator ( in blue ) because when I apply filler to the two halves, there will be fillets ( in red ) adjacent to the separator plate . Then i will split the two halves and rejoin without the seperator plate and smooth away the fillets as per pic 4.

The separator plate needs to be semi rigid, very smooth finish on both sides and waxed to allow easy removal - some form of smooth plastic maybe ?

Hope you've still got all your fingers Kevin. 'Elf 'n Safety would have produced a multi-page manual to stop you doing that with a drill press.

Well Brian, the H&S police havn't paid me a visit yet - so all good so far !

Now on the 5th cycle of primer filler and cut back - a few more to go yet before the plug can be used to produce a good mould.

Top quality work there Kevin. Well done.

4 more cycles and nearly there - I discovered a high tech solution to separate the two halves during the process - its called sellotape !!