Well to "The Dark Side" I go a-venturing!
This held me up for some time trying to figure a way to attach the bottom of the fuse on a Phase3 F-16 with out glue or tape - both kinda permanent when a paint job is involved.
Came to me late at night of course - then couldn't sleep...
I machined the mold that I use to make the screw mounts that hold the top and bottom fuse together.
I like the servicing aspect of any design and especially the P3 F-16. This feature provides upgrade possibilities to the power system down the road.
This production Rev. screw mount is shorter than the prototype. I think it looks a little better.
I glassed both the top and bottom fuse with WBPU and 3/4oz. fiber glass.
Take a Dremel with your choice of tip (I used a grinding stone tip) and make a recess for the screw indentation in the foam to receive the screw mount. I used White Gorilla glue as it will expand and backup the recess when attached to the fuse with included screws. Be careful with the Gorilla glue - don't use too much as it will creep out around the edge and make a mess. Canopy glue works well around the outside edge. And I recommend rounding the two corners. I didn't - wish I did.
The Fuse Prep:
Install the bottom fuse. Poke a hole through the flat on the screw mount and mark the upper fuse with the poker. Remove the bottom fuse and mortise in (make flush with mating rail) a small rectangle of lite-ply, Gorilla glue the ply into the foam.
Temporarily re-install the bottom fuse, mark the ply and drill (.040 or 1mm). Run a screw into the hole, back the screw out and run some thin CA in the hole to harden the threads in the ply. Let dry and then install the bottom fuse and wha-La! you are ready-5
Worked out rather well I think.
New addition of Cheater Hole Support 12-11-08 Rev.2 added internal lip for more rigidity