Here I started by cutting the 60" UND strips that will go over the stiffeners.
Then I cut the BID strips. Since the plans call for a 45 degree orientation, I had no other choice but to use 2 strips to span the entire 103" length (then double for the other fuselage wall).
Before glassing the top longerons, a fillet of flox goes on the lower lip of the top longeron. This is to aid the fiberglass cloth to curve around the edge. Here I am using the 'baker's icing on the cake' trick.
Oooooooo... that is a nice looking fillet if I may say so myself!
Since I wanted to glass the left AND right fuselage longerons on the same day, I laid both fuselage walls on my 'temporary' table. This left my workshop table free so that I could prepreg the layups.
Prepregging - this was harder than I thought. I laid the 3 strips of UND, poured resin in between like a lasagna and squeegeed it out. I then folded the top plastic piece over and cut the strip with a nice edge (the edge that would go on the lower lip of the longeron; the top edge overhangs and gets knife trimmed later). When I went to peel the top plastic off, it pulled the top layer of fabric off with it, making a mess! I fixed it back up the best I could, and positioned it onto the longeron (the middle section where the stiffener is located).
Here is an overview shot of the UND installed.
Close-up of the UND strip that transitions from stiffener to longeron.
I then repeated this process for the left fuselage wall.
Here is a close up of the peel ply and glassed top longeron.
I left a considerate amount of overhang. This was because I did not want to knife trim since I was afraid disrupting the layup would introduce unwanted air bubbles. Instead, I opted to let it cure as is, and use the vibrating cutting tool and router to trim later.
After a full cure, I used the vibrating multi-tool to cut the edge as flush as I could. I made sure not to cut into the longeron or foam. Notice how I left about 1/8" overhang. The router will later trim this flush.
Ryobi router to the rescue! Damn I love this thing! Using the router, I flush trimmed ALL edges flush to the lip of the longerons.
Here is a better angle showing how the flat bit roller rides along the longeron, cutting everything above perfectly flush!
I took a picture halfway into the trim to show the 'before' and 'after'. Notice how the router cuts the foam AND the fiberglass perfectly flush to the longeron.
This worked so well I then flush trimmed the lower longeron edge flush using the same method.