Despite my prep work last time, I am not ready to start building the fiberglass seat pan. I need to fabricate a steel hoop to tie the two halves of the rear of the frame together. Unfortunately, Lowe's had 1/2 inch diameter steel tube, and they had 3/4 inch solid round steel, but they did not have any 3/4 inch diameter steel tube. Consequently, I'll probably pay a visit to some of the airplane shops at Merrill Field some time this week to see if I can round up some 3/4 inch 4130 chrome-moly. How sweet would it be to build the whole frame from 4130? Unfortunately, that's just a bit (a lot...) beyond my skill level :) Consequently, I decided to get started on the side panels to cover the electronic/battery bay.
In either case, it sticks out far enough that the foam plug has to be carved out to clear the boot, so I marked the approximate size of the contactor, dug out a piece of 60-grit sandpaper and started recessing the foam.
Unfortunately, at this point, after test fitting the foam, I dropped the foam plug and broke off a corner. Okay, no problem -- as we've already mentioned, you can simply glue pieces back on if you make a mistake. The fiberglass needs to be smooth, presentable, and attractive, but the foam plugs can be a hodgepodge of glued together pieces, so long as you can sand them smooth before starting your lay-ups. However, as I mentioned up above, the spray adhesive I bought doesn't stick very well, or at least doesn't provide much initial tackiness. So, I glued the pieces back together and set them on my work table to dry.
To be continued...