Thank you all for your words of support on this and all your helpful suggestions.
Sorry I haven't posted much for a while, its not that nothing has been happening, quite the opposite in fact.
The console construction is well under way as you can see from the photos. I am using West System 105 epoxy mixed with colloidal silica to give me a paste suitable for filleting all the joins in the plywood. It seems to be working a treat...epoxy is great stuff, it allows you to easily patch up in mistakes you've made in the measuring of the panels! I am holding the plywood panels together with zipties while the epoxy sets (known as the stitch and glue method....used to be used years ago with copper wire to make small plywood boats). The good thing aboutt he zipties is that epoxy doesn't stick to them (very well) so they can be pulled out (with a bit of force and swearing) once the epoxy has set.
A quick guide to epoxy filleting if anyone is interested:
1. drill holes for zipties in both panel to be joined
2. sand panels to open pours and "de-burr" the holes
3. make sure everything is to hand and then mix first small batch of epoxy
4. coat the areas to be joined/filleted with neat epoxy to prime the wood
5. mix colloidal silica in with the remaining epoxy to a peanut butter consistancy
6. slap on a "bead" of epoxy paste onto all joining edges
7. wack edges together and put in zipties. Ensure all edges meet and zipties are tight.
8. mix more epoxy/silica if needed (if you had any left, its probably gone off by now), and start constructing fillets by using the rounded end of a wooden mixing stick
9. thoroughly coat ones hands/hair/face/arms/legs with epoxy
10. leave to set and then pull out zipties with pliers. Fill in any holes at a later date.
Once all the panels are glued together, we will round off all the corners, then coat with G4 varnish (to provide a better adhesion of the polyester resin), lay up layers of GRP followed by tissue (to even out surface), fill and fair with resin mixed with glass bubbles (easy to sand down), then apply paint system.
Also done today was the mounting of the engine! No problems encountered here except the arm on the trim sender snapped off when we tilted it up (no idea why) so may try and fix that with epoxy!
Suggestions/comments always welcome.
1. The shiney new aluminium fuel tank that I had made for.....the price of a bottle of Scotch
- approx 70 litre capacity
Its sitting on the flange of the console to check its all ok
2. sanding/drilling all the panels ready for assembly
3. Me doing the first filleting to be done on the lower console section
4. Mike and I filleting away
5. The almost finished lower console section