Taping the bulkheads

So now that the fuselage sides were bonded (with flox) to the bulkheads, it was time to apply the BID tape to the bulkhead / fuselage mating edges. Basically, this acts like a fiberglass "L" extrusion that supports the bulkhead onto the fuselage sides. The plans say to do this while the flox is still wet; but since I was limited on time, I had to do this step after everything had cured.

Step 1 was to cut the BID tape strips. At first, I thought BID tape was something you bought 'off-the-shelf'. But it turns out, BID tape is simply strips of BID (about 3" wide) cut to the length you need. They have a 45 degree orientation.

The plans aren't clear on whether or not the firewall receives a few strips of tape; I figured it couldn't hurt so I cut some for the firewall as well.

After cutting the strips, I prepped my bench to prepreg the strips. I started by laying a strip of cling wrap onto my table top...

I then placed a strip of BID tape and poured resin onto it... squeegeed it out (wetted it out), applied another layer of tape and wetted it out...

 I then cut the strip to the proper length to give me a nice clean cut. Notice how I cut the cling wrap WITH the fiberglass.

I then prepped the bulkhead/fuselage mating surface by sanding it smooth and brushed on some resin to the surface.

 I then applied a bead of flox using the "bakers icing on the cake" trick.

 I then lifted the prepregged fiberglass 'tape' off my bench... and applied it onto the mating surface.

I applied it with the cling wrap on the outside, positioned it in place, and then peeled the cling wrap off like applying a band-aid. I then used a brush to tuck the fiberglass into the corner and removed any air bubbles.

 I then peel plied the edges.

This process was then repeated MANY more times... for the front seat (forward, aft, left and right sides), the rear seat (forward, aft, left and right sides), the instrument panel (forward, aft, left and right sides)... you get the picture.

Here is the rear seat...

Showing the cling wrap prepregged fiberglass tape being applied like a band-aid...

Peeling the cling wrap off. Notice how I let the tape extend past onto the through holes. This is easily trimmed using the dremel tool after its cured.

Getting rid of air bubbles...

And vuala! BID tape applied!

Here is the F22 bulkhead. The plans only has you apply tape to the area outlined in red for now. It later gets reinforced in later chapters. Here, I sanded the area dull, brushed on resin to the mating surfaces and applied a bead of flox to the corner.

I then applied the prepregged tape and peel plied the edges for a smooth transition.

Here is an example of taping the instrument panel; same procedure here... sanded the mating surface dull, brushed on resin to the mating surfaces and applied a bead of flox...

and then applied the prepregged BID tape.

Same thing with the front seat edges...

After all the tapes cured overnight, I then trimmed all the through-holes (using the dremel tool) and sanded everything smooth and flush!

I turned the fuselage over on its side to make it easier to sand all the edges smooth!

And there you have it! All the bulkheads 'taped' to the fuselage sides!

Next up... the F28 bulkhead and doublers!