Before I could sheathe the cockpit section of the fuselage, the cockpit floor had to be installed first. Instead of using plywood as originally planned, it is now a composite construction. The floor consists of carbon fibre fabric with a foam core and an additional layer of Kevlar fabric. The latter is there to protect the pilot, considering the breakage characteristics of carbon fibre.
With my limited experience in composite construction, it took a lot of time to first create the moulds in acceptable quality. I now know that the key to success here is the hours of sanding work. Later, I also learned that using too little mould release agent leads to the mould tearing.
