Fiberglass work
I'll chime in as to what works for me. Definitely other techniques to experiment with. "Aluminum" above has some excellent points on cutting and sanding. The materials and techniques are just some that are used. You will find that some work better for you and others not so much. Mix and combine for various applications. You will definitely need techniques refined when the windscreen comes into play. Nothing to be afraid of, just a new skillset with its own tools and materials. The nice thing about fiberglass - if/when you screw up, grind off and re-do.
For the VS closeouts I just allowed epoxy/glass to cure on flat table (between 2 pcs of plastic, then cut to desired shape. For HS close out, used aluminum sheets to form angled surface matching trimmed surface. Applied direct to blue plastic surface and add one layer of plastic sheeting on top. Both applied to outside of trimmed end caps (cleco?d in place) {If the 1/8" spacing is a concern, you can cut back a bit off the end caps to compensate} with glass/flox mixture. Next day, remove clecos and apply flox?d filler or small glass strips to inside to reinforce joint.
After final attachment, I use ?thin? glass cloth (approx. 1? wide) over the alum to fairing joint as described below ? with the peel ply on top. After cured remove peel ply, roughly sand smooth, then with squeegee apply thin layer of fiberglass with Microlite filler (soft peanut butter consistency). Allow to cure and sand smooth. The Microlite is very similar to auto body filler in texture and use..
Materials I use:
Glass cloth (woven not the cheaper mat)? various thicknesses. Unfortunately, I don?t recall the specific thicknesses. Left over from previous build..
Flox (flocked cotton fiber)
Peel ply ? place over final coat to soak up excess liquid and leave smooth (relatively) finish.
West Microlite ? very fine fiberglass filler/thickener
West Systems Fiberglass (1.2 gal kits ? with 206 slow hardener)
West pumps for gal kit (measures correct glass/hardener ratio in quick pump)
Rotary cutter (OLFA is one from Aircraft Spruce)
Chip brush 1? wide (cheap disposable ? home box store) trim bristles to approx. ?? long
Acid brush (cheap disposable ? Amazon/ harbor freight) trim bristles to approx. ??
Plastic sheeting as required..
Technique I use:
Roughly cut cloth oversize & Place on plastic sheeting
Wet out with mixed epoxy
Place 2nd plastic sheet on top
Use squeegee, fingers, what ever to move liquid around to completely wet cloth)
Cut ?wetted? cloth with rotary cutter to size required. Cut through sheeting both sides.
Peal off one layer of plastic, transfer to part surface and place on part with plastic up
Peal plastic off.