The shaping is nearly complete. I’m finally cutting around the edges so the panels will come loose again. The pattern on the panels gives the shell a different look. It reminds me of something that happened a long time ago in a galaxy far far away…
Learjet 45 Simulator Shell
I’m making great progress with the final shaping. Unfortunately, the foam putty I’m using is hard to get locally and in limited supply online too. I have to order it and wait for the next batch to arrive in order to progress further. I’m also being my usual perfectionist self, so that doesn’t help either.
It’s looking good though and there are only a few rough spots I need to clean up on the sides and the top, so sealing and painting will happen soon. I wasn’t as careful with applying the putty, and it got in the spaces that it shouldn’t have, so I’ll need to carve around the edges to get the panels to pop out like they’re supposed to. I’m not worried about that at all. It’s just one more thing on my list.
Learjet 45 Simulator Shell Side View Close-up
Learjet 45 Simulator Shell Front View
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Um, yea. This sanding bit is taking much longer than I expected. Big surprise huh? 
If I do this right, I shouldn’t have too much touch-up work after this sanding pass.
Learjet 45 Simulator Cockpit Shell Port Side Foam Putty Skim Coat
Well, the port side final shaping is under way. I’m using adjustable flexible sanders from AFS that are typically used on cars, but they work great on any curved surface.
Learjet 45 Simulator Cockpit Shell Final Shaping
Learjet 45 Simulator Cockpit Shell Shaping Close-up
AFS Adjustable Flexible Sanders
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I’ve been battling bronchitis, so the last few weeks haven’t been very productive. Sanding tends to be bad for already irritated lungs. I’m ready now, with respirator in hand, to start the final sanding and shaping of the foam on the outside of the shell. After that, a coat of hardener and some green paint and then it’s on to the work I’ve been really wanting to do on the interior. Expect more activity here in the coming weeks.
The rough shaping and sanding is done. Final sanding requires a guide coat, so I found some old acrylic paint I had sitting around and used that. What, you thought I wanted a purple plane? Only if I was Prince or a rabid Vikings fan.
Learjet 45 Simulator Shell with Sanding Guide Coat Applied
Just a quick update on my progress:
Phase 1: Rough trimming -Complete
Phase 2: Rough shaping -In progress
Phase 3: Foam putty (Fill in bubbles and other voids) -In progress
Phase 4: Final shaping (Various automotive block sanders) -Not started
Phase 5: Foam hardener -Not started
Phase 6: Paint -Not started
Learjet 45 Shell Foam Shaping Progress
…took longer than expected, but the Bondo finally cured, and I was able to fill the shell wall voids with foam. It was more than a little surprising that it took so many cans to get it done- 12 in all. The clerks at the local hardware store where I was buying all this spray foam were, not surprisingly, giving me the twenty questions routine. I’ve learned that telling the truth in these situations is not always the best policy.
It needs to stabilize for a few days before I can start trimming and sanding it down.
Learjet 45 Simulator Cockpit Shell with Foam
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Smelly and messy is all I can say about that stuff. Make sure you get some ventilation and/or wear a respirator when working with it.
In preparation for the foaming process, I am filling the grooves (fluting) I made in the outside of the hardboard wall pieces with Bondo to help strengthen and keep their shape if things ever need to be disassembled. The filler foam will be sprayed on top of that and then shaped with hand tools and automotive finishing sanding blocks (used for body fenders and such).
Learjet 45 Shell (Now with Bondo!)
