> For complex shape like this I find it easier (and better) to do the hard
 > coat and mold release than use duct tape.  I also have found that the
 > polyester 'Paint n' Patch' that you can get at the hardware store

makes a

 > very nice filler to use for any holes or irregularities on the urethane
 > mold.  I mix the epoxy slurry to about the consistency of thick

paint and

 > put it on with a brush.  Gives a very smooth surface.
 >
 > Attached pic is heater housing I made with similar approach.
 >
 > Al

Al,
Nice job on the heater distribution molding.  I take it that the entire unit
sits in the cabin area so that only cabin air is being heated by the heater
core.

What is the size of the heater core (dimensions), and what is the weight of
the blower motor?

Do you find that you need to destroy the mold to get the part off?

Are you planning separate ducts to windshield, etc? if so, what are you using
for the control of the air flow -- I have found normal "heat boxes" to be
very expensive from Aircraft spruce, etc.

Bill Schertz
KIS Cruiser #4045

You can make a very nice valve from alum tube if you have a friend that
can heliarc (TIG) weld.  Make a T from the appropriate sized tube (with
cutouts to interconnect, of course) weld, and use a pair of grommets for
bearings,
an appropriate (~3/16 to 3/8) steel or alum tube for a shaft and make a
pair of elliptical aluminum (~.025 - .032) valve flaps.  Form them half around
the shaft, rivet a sheet of engine baffle edge rubber between the two for
a flexible edge seal and drill thru the two flap aluminum sheets and the
shaft for a pair of attachment bolts (~6x32).   Assemble, add an operating
arm and you have a nice valve.   I made mine like this for carb heat and
cabin heat.   If this is not clear, I can make up a couple sketches.   Not my
idea - got it from Long EZ plans. Simple, reliable easy to make. I also have
made some intricate ducts much like Al's - one of the wonderful things about
composites.   We can make any type of duct pretty easily, and pretty light.

 Bill
Long EZ builder & pilot
mechanical engineer

"Simple, reliable, easy to make" ... you have just uttered my mantra, Bill.  Was this
a Rutan design?  Please take the time to do the sketches, or a scan, or whatever.  I
am pretty good at "mind engineering", but a graphic still helps a bunch, Thanks,

Dale Smith

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