Fuse sidewall gusset materials

[Jaws136 4]

So got all the templates cut for some epoxy in gussets in the fuselage below the doors what materials are people having luck with holding up? Aluminum, chromoly, sheet metal, plywood? And what epoxy seems to work best? Planes a mk4 with airdale backcountry gear. Thanks guys!

[1avidflyer 1983]

I used .040" chromoly, but it was welded in, not epoxied.  This is my Kitfox 4, you can see how I widened the fuselage in the second picture.  JImChuk

[Jaws136 4]

That looks great Jim. Ive had the top pic saved along time on my phone. Lol. Unfortunately my planes all covered and complete so im guessing epoxy is the way to go, with that im wonderingbwhich materials would bond best.

[Jaws136 4]

So it looks like T88 epoxy is the choice for curing in colder climates. Now ideas for material? Plywood thickness? 1/8th? Or 1/16 aluminum? Suggestions?

Edited 12 Sep 2019 by Jaws136

[1avidflyer 1983]

I would think T-88 is more of a glue for wood.  It is pretty runny as well, I doubt it would stay in place in your case.  I think either scotch weld 2216 or Hysol 9460 would be a better choice.  (these are the epoxies Avids and Kitfoxes have used to glue the ribs to the spars in the wings)  And then mix the epoxy with cotton flox to thicken it so it stays in place till it hardens.   JImChuk

[Turbo 162]

Just my 2 cents, but I'd sure use something with some compressive strength, like high quality 1/2" plywood, or thicker.  It should be a tight fit between the tubes, inside the triangles.  1/8" won't do much at all, other than buckle!  I have 1/2" ply in my seat truss area, held in place with zip-ties.