Making a fwd deck with no mold

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Start with 1 airplane - 9/15/2013

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Step 1.  Form the deck out of Home Depot pink foam.  (tip...try not to use any spray foam or drywall mud for shaping.  It will make the later steps easier)

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Step 2.  Remove the plug from the airplane and using a handheld router with a small flat bit set to 1/4 inch depth, route the plug with ~1 inch spaced channels in 2 directions (see photos)

(tip...this is when you benefit from no drywall mud)

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Step 3.  Now use the router to remove more of the material, but leave enough high spots so the router will not gouge the material.

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This is what you should be left with

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Step 4.  Using a large rasp file remove the high spots.

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This what you will be left with.  A plug that is now 1/4" smaller than when you started.  It is in the space that we will layup our fwd deck.

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Step 5.  Adding the stiffners.  First, set your router bit set to a 3/4 inch depth.  Then layout your pattern with a marker on the foam plug and run the router along your lines.  Next, use a small saw to open the groove to a V patters and finally you will flare the edges with some 80 grit sandpaper.

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Step 6.  Mix 3 cups 20 min drywall powder to 1 cup flox and add warm water untill drywall paste is like runny syrup.  Slather it on the plug and led dry for 24 hours.  Sand and apply a coat of KILZ stain blocker/primer.  Next put 3 coats of your favorite latez paint on and let dry.

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Step 7.  

Plane ready to move

This tail is similar to one I plan on building for my KR2S-Seafury

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Some other Stuff

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Some pictures of my el-cheapo powdercoat system.  Just a 55 gal drum, torpedo heater and a Craftsman powercoat gun using Harbor Freight powdercoat paint

Tailwheel is now mint green because the zinc phosphate primer bled through a little.  I guess the primer needs more than 24 hours to dry.  All parts will get an enamel topcoat anyway