The Corsair82: 82% F4U-1A Corsair

The Shop

Here are pictures of the basic design and construction of my shop. Having a good place to build is Invaluable. The time it took to build mine was more than paid back by the savings in time building the Corsair.

Shop 01 After two attempts at building the Corsair replica, I decided to start from the begining. I needed a shop that had the room for the project and the tools required to build it. It will also house the finished aircraft.
I started by building what resembles a covered bridge. The front and rear walls (missing in this picture) are not structural. I got all of the materials at a building supply store that was going out of buisness. That saved me more than 50%. I also built it myself, (with the help of friends,) saving the cost of a contractor.
Shop 02 In this picture you can see that the back wall is solid. No back door for security reasons. There is a large window that is about ten feet off the ground. The front "door" is 36' wide. I built it like a bi-fold closet door. Each door rides on a top rail and a wheel at the bottom.
Shop 03 Here you can see the three foot entry door located on the right door half. This allows entry without having to open the large doors. This is especially handy when maintaining a set temperature and humidity while curing parts.
Shop 04 I'm a real scrounger. All the lights came from a building that was being torn down. The contractor was happy to let me cart them away. Notice the big wall fan under the window. This is a must have item in a shop where fiberglass is being worked.
The corner on the left is a bathroom with sink, shower and toilet. My wife said I had to leave the house clean and return to it clean. On top of the bathroom is a heat pump I got from a friend who was replacing his home unit. It is not for comfort. It is used to remove the humidity from the air when I do layups. Humidity will ruin layups.
The insulated barrels next to and above the bathroom is storage for hot water. I have a solar heater in back of the shop which runs hot water through the floor. This system came from another building that was being torn down. Some times I have to run the AC and heat at the same time so that the humidity is low, but the temp is high enough to cure the layup.
The door on the back wall is the entry to my tool room. It is a lean to shed (8' x 16') that was added on as a storage room. I later converted it to a tool room.
Shop 04 The windows were a discontinued item because of their strange size. They were perfect for me. They let in light and air, but are too narrow for anyone to get in and out of. The shop doors require a key from inside and out. Security is a real concern for me.
QuickTime Video Climate Control

In this video I talk about the climate control system I installed in the shop. Keeping temperature and humidity under control is extremely important when working with composites.
QuickTime Video Solar Panels

In this video I show the solar panels that heat my shop.
QuickTime These videos are in QuickTime format. You can get the QuickTime plug-in and player for free from Apple by clicking the logo to the right.
Click on any picture to see a larger version
(Click on the QuickTime logo to go to the page to view the associated video.)

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