Seat #2

We were unhappy with the first seat we made.  We glued ribs on the bottom of the shapped seat, then fiberglassed the top, then between the ribs on the bottom.

This was not strong enough, so we decided we probably would have been better off fiberglassing all the way around the foam sheet, then adding the ribs to the bottom.

So, we setup the Hotwire Bandsaw (Pictured at left) and made a new template.  We also decided that the bucket of the seat should go lower.  We can always add padding, but we would never be able to remove anything to enable a taller person to clear the canopy.

The Template was connected to the foam by 4 nails pushed into the foam. This works well and is easy to work with.  Pictured at left, I am cutting one of the 4 pieces using the template and the foam bandsaw.

When using the foam bandsaw, I always try to push away from the table so the hotwire stays vertical and does not impact the edges. 

Below are the 4 foam ribs that fit between the spars for the seat.  They all came out great.  You can only see 3 because the third is behind the side of the fuselage.