The Champ is geting to that 99% completed with 75% to go stage, but I have kept the Long EZ Project moving as best I can. The last couple of weekends, I have prepared all the templates required for the entire project.
For template material I used a sort of particle board that was used as a shipping protector for sheet aluminum shipped on a pallet. It is 1/4 inch thick and cuts like butter and is a wonderful material for templates. I attached the paper templates to the board with WEST System 205 epoxy. I put a skim coat straight on to the board, laid the patterns on the board, and then coated it a with a pretty heavy coat sqweeged over the paterns.
A couple of hours later, after the epoxy had cured, I cut the templates on a bandsaw. In the picture above you can see that I have yet to complete the final contouring on about half of the templates. A Long EZ “Guru” might notice that the lower template for the lower winglet is missing. That is because I don’t plan on installing the lower winglets, as many builders have noted that the aircraft does not notice them being gone. Besides the Beech Starship doesn’t have lower winglets!
Al Wick, a Cozy builder from Portland,is going to let me borrow his hotwire saw to cut my cores. Cheers, more later.
(see Al’s link to the left)

(UPADTE 4-13) I visited Al Wick and his very cool Cozy this morning.  His ability to “see” system failures before they happen then and ” build-the-safety-in” to the Cozy to assist in preventing them is truly amazing.  Thanks Al, for the loan of your Hot Wire Saw!  I hope to be cutting foam within two weeks.