Chapter 8

Headrests, Seat Belts & Heat Duct

This is a chapter with a lot of little stuff to do. Some of it I think is completely out of order and I will wait to finish these parts. But most of it seemed easy when I was reading...I guess I still haven't learned that Nat has the ability to make the most troublesome layup seem easy.

First on my list was to install the hardpoints for the seatbelts(I am a bit out of order here because I was still finishing Chapter 7 at the same time). Cutting the plywood was simple, I used my dremel to cut the bevel for each piece. In place of the 7 ply layup I used 8, no particular reason other than it was easier to layout the blocks of cloth that way. I put a lot of wet flox on the back center of each plywood block and mashed it into place. The excess served to help round the corners onto the block for the layup. I created the layup on some freezer paper (Krogers was out of wax paper), and then put it in place. This was quick and easy.

Next on my list was the front shoulder hardpoints. The ledge of the shelf was easy to construct and fit almost perfectly the first try. A little change to the notches and viola! I glassed the inside, and waited for it to get tacky and then floxed the ledge in place, this was a little more difficult than I thought it would be because of the care that I was taking not to pull the curing glass loose. The next layup required putting the 12 layers of 1.5" bid square in the holes. This was not fun since everytime you cut bid it streches into a different shape. It was quite difficult to cut the little squares just right. Thirty minutes later I had the layers built up, and amazingly enough they fit perfectly. I then added the two layers of bid over the shelf and the 3plys of UND over the hardpoints and onto the seatback (this ensures that you will be dead before the seatbelt breaks). I had to use a small amount of flox under some of these points to get them around the 135 degree angle. All was done...Except for in the corners, where I opted to tape instead, this seemed like the simplest solution.

I went ahead and cut the .125" extruded aluminum angle for seatbelt attachment, but did not install them yet. I want to finish the interior layups first, so I don't get epoxy all over them. Also, I still need to install the nutplates in the shoulder support. I am not sure when I will do this. Nat says when you first install the seatbelts, my fear here is that I will flox the bolt in place with the nutplates, so I am waiting...don't know when I will put them in.

I constructed the headrests...although I don't know why, I can't put them in until after chapter 18...that seems like a very long way away right now. For some reason, I made them incorrectly the first time, so now both headrests have a front and a back. But they look nice..... for coneheaded people. Many builders complain about their shape, and while I don't care for it, they are simple to construct and do provide some (albiet small) protection should I ever try to stop upsidedown.

Shoulder support	Front hardpoints
Headrest Assembled