Fuselage Pod Construction

Fuselage Pod Mold

Pod Framework
The pod framework was layed-up on a flat mold (sheet of 1/8 6061-T6). All framework parts were made of 7725 glass over 1/4" foam, with the exception of the main frame, which was 3/8" foam. Phenolic hardpoints were added to the foam before layup, and unidirectional carbon was installed to carry landing gear and strut loads.

Fuselage Sides

Pod Assembly
The pod was assembled in September 2006. Diamond-shaped reinforcements have also been added over the wing mainspar and drag link attach points, and the lap belt reinforcements were carried around to the belly. The original nose design used a rectangular front window with a carbon arch for reinforcement. After sitting in the pod it was clear that this would block a lot of the forward vision, so the reinforcement arch was cut away, and the sides of the front window were opened up to maximize the viewing angles.