Charles' Cozy Mark IV Project

Serial # 1394

Website last updated on: March 8, 2016

Page updated on: June 1, 2015
March 8, 2016

Chapter 24 - Armrests, Seats & Fairings


Quick links within this page:

Step   1 - Map pockets
Step   2 - Front armrests
Step   3 - Front seat thigh supports
Step   4 - Rear seat armrests
Step   5 - Heat duct cover
Step   6 - Back seats
Step   7 - Landing brake and battery cover
Step   8 - Canard cover
Step   9 - Strake fairings
Step 10 - Wing centerspar seal
Step 11 - Optional ice shields

Chapter Overview

This chapter covers the manufacture and installation of:

  • map pockets
  • front seat armrests
  • front seat thigh supports
  • back seats
  • back seat armrests
  • back seat thigh supports
  • heat duct cover
  • landing brake cover
  • battery bulkhead cover
  • canard cover
  • cylinder blister fairings

The front and back seat armrests, heat duct cover and landing brake cover require a lot of fussing fitting which is very time consuming.

Step 1 - Map Pockets

In this step the map pockets are made and then installed. I made the map pockets to the size specified in the plans. When I went to install them, I discovered they were several inches too high. I double-checked all my measurements and they were spot on. What I plan to do is to trim them to size after the arm rests are installed.

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The foam I used as a mold for the fiberglass.


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I rounded the corners so it would be easy to clean the dirt out of them.

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Two layers of BID used to make the map pocket.

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The finished map pocket.

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Right caption


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Before mounting the map pockets over the brake lines, I put micro around them so there would be a smooth transition over the brake lines. This will make it easier to remove items from the pockets as there is less chance of items hanging up on the brake lines when they are being removed.

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The installed map pocket.

Step 2 - Front Armrests

The arm rests are real "fiddly" structures. The top of them are easy to make. The one inch vertical piece used to clear the aileron torque tube is easy. The angled piece which goes from the bottom of the 1 inch vertical piece to the side of the fuselage is real fiddly. I have spent several hours using cardboard templates trying to get it correct. The problem is the side of the fuselage curves and the width of the armrest changes. Also, you must contend with the angled seatback. Making a piece to fit this area and look good has been challenging.

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One of many cardboard templates made trying to make a good fit.

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Assembling the pieces of the armrest.


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Test fitting the foam for the left armrest.

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Test fitting the foam for the right armrest.


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Test fitting the left armrest.

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Test fitting the right armrest.


Step 3 - Front Seat Thigh Supports

The thigh supports are really easy and fun to make. Start out by making the ribs which attach to the fuselage floor. Then the thigh supports are cut to size and fiberglassed on one side. Horizontal saw cuts are made through the foam to the fiberglass. These saw cuts allow the thigh support to be shaped to the ribs. The saw cuts are filled with micro and fiberglassed with two plys of BID.

The plans have the thigh supports made after the ribs are installed in the plane. However, I didn't feel like bending over the fuselage side to work on the fuselage bottom, so I decided to make them on the bench. It was much easier. The pieces are held together with hot melt glue while the fiberglass cures.

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The foam for the thigh supports is in the upper left of the pictures and the foam for the ribs is in the upper right.

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The foam for the thigh supports is in the upper left of the pictures and the foam for the ribs is in the upper right.



Step 4 - Rear Seat Armrests

The rear armrests were much easier to make. I guess the practice we had making the front seat armrests paid off.

The armrests are made with one ply of BID on the inside and two plies of BID on the outside.

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The foam for the rear seat armrests are shown at the bottom of the picture.

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The foam for the rear seat armrests are shown at the bottom of the picture.


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The finished rear seat armrests.

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The finished rear seat armrests.


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The forward part of the rear seat armrests will be between the back of front seat and the airleon torque tube support. I wanted a good attachment to the torque tube support for both the forward and aft portions of the armrests so I removed the foam on the forward part. When the aft portion is put in place, it will fit over the cutout portion of the foward piece.


Step 5 - Heat Duct Cover

Details of step will go here

Step 6 - Back Seats

Details of step will go here

Step 7 - Landing Brake and Battery Cover

Details of step will go here

Step 8 - Canard Cover

Details of step will go here

Step 9 - Strake Fairings

Details of step will go here

Step 10 - Wing Centerspar Seal

Details of step will go here

Step 11 - Optional Ice Shields

Details of step will go here