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Cozy MK IV

The process of building an Experimental Airplane

  • About Cozy MK IV (and me)
  • Specifications
  • Useful links
  • Project Pages
    • Chapter 3 – Education / Composite Techniques
    • Chapter 4 – Fuselage bulkheads
    • Chapter 5 – Fuselage sides
      • Step 1. Cutting the jigs and laminating the top longerons
      • Step 2. Building the forms for the fuselage sides and preparing the sides for contouring
      • Step 3. Contouring the insides
      • Step 4. Inside layup and installing the upper longerons
      • Step 5. Installation of lower triangular longerons
      • Step 6. Completion of the fuselage sides
    • Chapter 6 – Fuselage assembly
      • Step 1. Assembly of the fuselage sides
      • Step 2. Center keel and seatback brace
      • Step 3. Contouring and installing the fuselage bottom
    • Chapter 7 – Fuselage exterior
      • Step 1. Building the NACA-scoop
      • Step 2. Contouring the bottom
      • Step 3. Glassing the bottom
      • Step 4. Contouring the sides
      • Step 5. Glassing the sides
    • Chapter 8 – Head rests, heat duct, seat belts and step
      • Step 1. Carving the foam pieces
      • Step 2. Glassing the inside surface for wet layup
      • Step 3. Glassing the outside of the shoulder support
      • Step 4. Glassing & Installing the headrests
      • Step 5. Installing shoulder harness attachments
      • Step 6. Installing the outside seatbelt attachments & external step
      • Step 7. Center seat belt attach
    • Chapter 9 – Main landing gear and landing brake
      • Step 1 – Landing gear bulkhead reinforcements
      • Step 2 – Preparing the strut for installation
      • Step 3 – Attach-tabs and installation
      • Step 4 – Landing gear cover
      • Step 5 – Installing axles, brakes and brakelines
      • Step 6 – Constructing the landing brake
    • Chapter 10 – The Canard
      • Step 1: Trimming the foam-blocks and cutting the cores
      • Step 2: Making lift tabs, Inserts, Jigging cores, Laying up the shear web and installing lift tabs
      • Step 3: Jigging and bonding the canard sections together
      • Step 4: Spar Cap Layup
      • Step 5: Applying the bottom skin
      • Step 6: Installing hard foam blocks for elevator hinges, the upper spar cap, and the upper skin
    • Chapter 11 – Elevators
      • Step 1: Cutting foam cores and bonding to the torque tubes
      • Step 2: Installation of the bottom skin
      • Step 3: Installation of the top-skin
      • Step 4: Installing the NC-6 inserts and the NC-3 hinges in the canard
      • Step 5: Checking elevator travel and installing tip fairings
      • Step 6: Installing the pitch trim belcrank and the elevator mass balance weights
    • Chapter 12 – Canard Installation
      • Step 1: Fitting the alignment pins
      • Step 2: Aligning the canard
      • Step 3: Fitting elevators & torque tube to fuselage
    • Chapter 13 – Nose, Nose Gear, Pitot, Rudder Pedals and Brake Master Cylinders
      • Step 1: Reinforcing the Fiberglass Nosewheel Strut
      • Step 2: Fabrication of the NG-30s
      • Step 3: Installing the Jack Wilhelmson Electric Nosewheel Assembly
      • Step 4: Installation of the NG-30 Box Assembly on the Fuselage
      • Step 5: Nose Floor and Sides
      • Step 6: Installing the Rudder Pedals
      • Step 7: Installing the Master Brake Cylinders
      • Step 8: Completion of the Nosegear
      • Step 9: Piping the Pitot & Static System
      • Step 10: Closing the Top and Carving & Glassing the Outside
      • Step 11: Nose Door
      • Step 12: Skid plate
    • Chapter 14 – Central Section Spar
      • Step 1 – Centersection Jig
      • Step 2 – Assembly of foam parts
      • Step 3 – Interior Layups
      • Step 4 – Install the forward face
      • Step 5 – Outside hard points
      • Step 6 – Spar Cap Layup
      • Step 7 – Shoulder Harness Blocks and Outside Layups
      • Step 8 – Hardpoint Reinforcement
      • Step 9 – Access For Wing Attach And End Layup
    • Chapter 16 – Control System
    • Chapter 19 – Wings and Ailerons
      • Step 1: Building the wing jigs (and wing templates)
      • Step 2: Setting up the jigs
      • Step 3: Cutting foam cores
      • Step 4: Assembly of foam cores and lay up of shear web
      • Step 5: Bottom spar cap
      • Step 6. Bottom skin
      • Step 7. Top spar cap
      • Step 8. Top skin
      • Step 9. Wing ribs
      • Step 10. Ailerons
      • Step 11. Controls
      • Step 12: Attachment, wing to center section spar
    • Chapter 20 – Winglets and Rudders
      • Step 1: Cutting the cores
      • Step 2: Glassing the skins
      • Step 3: Jigging upper winglet to wing
      • Step 4: Inside layups (Right wing)
      • Step 4: Inside layups (Left wing)
      • Step 5: Outside layers (Right wing)
      • Step 5: Outside layers (Left wing)
      • Step 6: Lower Winglet Attach (Right wing)
      • Step 6: Lower Winglet Attach (Left Wing)
      • Step 7: Rudder (Right wing)
      • Step 7: Rudder (Left wing)
  • PPL-A
    • PPL-A Teori
    • PPL-A – Blokk A
    • PPL-A – Blokk B
    • PPL-A – Blokk C
    • PPL-A – Blokk D
    • PPL-A – Mørkeutsjekk
    • PPL-A – Utgått sertifikat!
    • PPL-A – Radiobruk
    • PPL-A – Simulatortrening
    • PPL-A – Pooleys CRP-1
Cozy MK IV

Chapter 7 – Fuselage exterior

In this chapter I will make the NACA-scoop on the underside and shape and glass the fuselage exterior.

Step 1. Building the NACA-scoop
Step 2. Contouring the bottom
Step 3. Glassing the bottom
Step 4. Contouring the sides
Step 5. Glassing the sides

Time used this chapter: 52:30 hours
Started: 2010-03-18
Ended: 2010-07-14

Project status:

The project has currently  been paused.

If someone is interested in purchasing the project, please contact me.

March 20, 2021:

Working on Chapter 16 – Control System

Last update: Step 4: Installation of Pitch and Roll Assembly

Accumulated hours so far: 1040 (since April, 2009)

Recent Comments

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  • Izzy on Canard Calendar 2020
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  • About Cozy MK IV (and me)
  • Specifications
  • Useful links
  • Project Pages
    • Chapter 3 – Education / Composite Techniques
    • Chapter 4 – Fuselage bulkheads
    • Chapter 5 – Fuselage sides
      • Step 1. Cutting the jigs and laminating the top longerons
      • Step 2. Building the forms for the fuselage sides and preparing the sides for contouring
      • Step 3. Contouring the insides
      • Step 4. Inside layup and installing the upper longerons
      • Step 5. Installation of lower triangular longerons
      • Step 6. Completion of the fuselage sides
    • Chapter 6 – Fuselage assembly
      • Step 1. Assembly of the fuselage sides
      • Step 2. Center keel and seatback brace
      • Step 3. Contouring and installing the fuselage bottom
    • Chapter 7 – Fuselage exterior
      • Step 1. Building the NACA-scoop
      • Step 2. Contouring the bottom
      • Step 3. Glassing the bottom
      • Step 4. Contouring the sides
      • Step 5. Glassing the sides
    • Chapter 8 – Head rests, heat duct, seat belts and step
      • Step 1. Carving the foam pieces
      • Step 2. Glassing the inside surface for wet layup
      • Step 3. Glassing the outside of the shoulder support
      • Step 4. Glassing & Installing the headrests
      • Step 5. Installing shoulder harness attachments
      • Step 6. Installing the outside seatbelt attachments & external step
      • Step 7. Center seat belt attach
    • Chapter 9 – Main landing gear and landing brake
      • Step 1 – Landing gear bulkhead reinforcements
      • Step 2 – Preparing the strut for installation
      • Step 3 – Attach-tabs and installation
      • Step 4 – Landing gear cover
      • Step 5 – Installing axles, brakes and brakelines
      • Step 6 – Constructing the landing brake
    • Chapter 10 – The Canard
      • Step 1: Trimming the foam-blocks and cutting the cores
      • Step 2: Making lift tabs, Inserts, Jigging cores, Laying up the shear web and installing lift tabs
      • Step 3: Jigging and bonding the canard sections together
      • Step 4: Spar Cap Layup
      • Step 5: Applying the bottom skin
      • Step 6: Installing hard foam blocks for elevator hinges, the upper spar cap, and the upper skin
    • Chapter 11 – Elevators
      • Step 1: Cutting foam cores and bonding to the torque tubes
      • Step 2: Installation of the bottom skin
      • Step 3: Installation of the top-skin
      • Step 4: Installing the NC-6 inserts and the NC-3 hinges in the canard
      • Step 5: Checking elevator travel and installing tip fairings
      • Step 6: Installing the pitch trim belcrank and the elevator mass balance weights
    • Chapter 12 – Canard Installation
      • Step 1: Fitting the alignment pins
      • Step 2: Aligning the canard
      • Step 3: Fitting elevators & torque tube to fuselage
    • Chapter 13 – Nose, Nose Gear, Pitot, Rudder Pedals and Brake Master Cylinders
      • Step 1: Reinforcing the Fiberglass Nosewheel Strut
      • Step 2: Fabrication of the NG-30s
      • Step 3: Installing the Jack Wilhelmson Electric Nosewheel Assembly
      • Step 4: Installation of the NG-30 Box Assembly on the Fuselage
      • Step 5: Nose Floor and Sides
      • Step 6: Installing the Rudder Pedals
      • Step 7: Installing the Master Brake Cylinders
      • Step 8: Completion of the Nosegear
      • Step 9: Piping the Pitot & Static System
      • Step 10: Closing the Top and Carving & Glassing the Outside
      • Step 11: Nose Door
      • Step 12: Skid plate
    • Chapter 14 – Central Section Spar
      • Step 1 – Centersection Jig
      • Step 2 – Assembly of foam parts
      • Step 3 – Interior Layups
      • Step 4 – Install the forward face
      • Step 5 – Outside hard points
      • Step 6 – Spar Cap Layup
      • Step 7 – Shoulder Harness Blocks and Outside Layups
      • Step 8 – Hardpoint Reinforcement
      • Step 9 – Access For Wing Attach And End Layup
    • Chapter 16 – Control System
    • Chapter 19 – Wings and Ailerons
      • Step 1: Building the wing jigs (and wing templates)
      • Step 2: Setting up the jigs
      • Step 3: Cutting foam cores
      • Step 4: Assembly of foam cores and lay up of shear web
      • Step 5: Bottom spar cap
      • Step 6. Bottom skin
      • Step 7. Top spar cap
      • Step 8. Top skin
      • Step 9. Wing ribs
      • Step 10. Ailerons
      • Step 11. Controls
      • Step 12: Attachment, wing to center section spar
    • Chapter 20 – Winglets and Rudders
      • Step 1: Cutting the cores
      • Step 2: Glassing the skins
      • Step 3: Jigging upper winglet to wing
      • Step 4: Inside layups (Right wing)
      • Step 4: Inside layups (Left wing)
      • Step 5: Outside layers (Right wing)
      • Step 5: Outside layers (Left wing)
      • Step 6: Lower Winglet Attach (Right wing)
      • Step 6: Lower Winglet Attach (Left Wing)
      • Step 7: Rudder (Right wing)
      • Step 7: Rudder (Left wing)
  • PPL-A
    • PPL-A Teori
    • PPL-A – Blokk A
    • PPL-A – Blokk B
    • PPL-A – Blokk C
    • PPL-A – Blokk D
    • PPL-A – Mørkeutsjekk
    • PPL-A – Utgått sertifikat!
    • PPL-A – Radiobruk
    • PPL-A – Simulatortrening
    • PPL-A – Pooleys CRP-1
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