Fiberglass help... Underside Layup

[baldcaldwell]

I would like to replace an aluminum panel on the bottom of my cabin with either fiberglass or CF. My reason for doing so...

The AL panel is originally a flat piece of .025. To install it requires shaping and bending to match up the screw holes. This creates multiple compound curves. Naturally the AL wants to spring back to it's original shape (flat) which makes it a real PITA to install and remove. This is an area that requires frequent panel removal for access to fuel lines/filters, boost pump and gear leg oleo struts.

In order to match the shape of the panel I would have to cast a layup in place and upside down. There is no way to remove the panel to perform the layup as it will not maintain the desired shape once removed.

Does anyone have any suggestions for casting a layup from the bottom of an original part?

My thought is...

• Cover the in place bottom panel with silicone (release) film
• Brush on epoxy resin
• Let tack up
• Layer on 8 harness fiberglass strips
• Let set
• Wet in the fabric and repeat.

This seems like a gravity fighting sloppy mess...

I am open to anything. I don't know or have the tools to shape AL, so that would be out of the question.

Thank you for any thoughts or insights.

Rob Caldwell