The following is a document that describes the files for printing out full sized bulkhead templates for the Cozy MkIV. I am contributing these files for free to all Cozy builders with the stipulation that I cannot guarantee their fitness for use. I have just started building the plane and don't know if any errors crept into my measurements of the original templates. I have printed them out on vellum and laid them over the originals and am satisfied that they are close enough and have accuracy that is at least on par with tracing the templates by hand. I know that the symmetry is perfect since the images are mirrored about the center. There are small differences with the curvatures, as matching up splines can never be exact, but the critical dimensions are the same as originals. It is very important that before you use any of the templates that you first print out a square of known size (i.e. measure it on the CAD system you are using) and see if your plotter scales it precisely in BOTH X and Y axes. If your plotter is not printing exactly 1:1, you may be able to scale it to fix it. For example, if a 10 inche square plots out to 9.9 inches in both axes, you might be able to correct by plotting at a scale of 1.01. I've plotted the drawings on an electrostatic plotter and found that they were reduced by .2% in only one direction. That doesn't sound like much, but it's about 1/16" over a 33" distance. The HP Designjet 650 produced output that was exactly on scale. It has been my experience that HP ink pen plotters are consistent at plotting at the scale requested. However, don't automatically trust the plotter, measure the output it before using it. Lay the plans templates over them and check them over a light table. Here is a brief description of the templates: F22: This drawing is shown in full scale with some of the parts that will mate up to it shown in dashed lines. I did not include the hole for the nose gear tube since I was advised that it's easier to position that hole while installing the nose gear. In addition, the individual pieces to cut it out are shown on a separate sheet so as to save foam. The sheet it's cut from is .2" x 24" x 48" 18lb. Last-A-Foam. I ordered 4 of these from Alexander Aeroplane thinking that they were 12" x 48" as specified in the catalog, so I got twice as much .2" foam as I needed. It is about $36/sheet so don't make the same mistake I did. Incidentally, the '95 catalog has the same error in it. F28: This part has the new curvature to give the nose a more rounded appearance. This change was made in Cozy Newsletter 36 by adding .7 inches to the height of the part. This necessitates re-curving the part and was my reason to use a CAD system to do the templates in the first place. It can be cut from the same 24" x 48" sheet as F22. Instrument Panel: This is the panel without the instrument holes since everyone will want something different. If you have access to a CAD system, the panel outline is a good starting point for fitting in your instruments and avionics. The bottom portions of the instrument panel can be cut from the same .2" x 24" x 48" sheet that F22 and F28 are cut from. Seatback: This part is almost too simple to require a template. I made this by creating the part in 3D, tilting it at a 45 degree angle, and punching all the features through it. This means that the solid lines are for the front for the and the dashed lines are for the rear. Although the plans say that the seat is inclined at about 45 degrees, if you do an arctangent on the dimensions that would give you that information, it may be closer to 41 degrees. [This is arrived at by the .65 " distance over a .75" thickness on the top taper.] UPDATE 6/6/95: While fitting my seatback bulkhead, I found an error. I must have screwed up a 3D operation and ended up with the wrong cutout on the top corners. The part still fits but there's approximately a 1" gap under the upper longeron. This mistake will be hidden by the headrest assembly and I've updated the newest file to fix this problem. In addition, the bottom corner cutouts specified in the plans don't really match the fuselage sides so I fixed them on this template. If you correct these corners it when you make the foam you'll save the hassle of having to sand them to shape later, after they've been glassed. In addition, the angle that the seat reclines is 47.7 degrees from the upper longeron (or 42.3 degrees from vertical), in case you're interested. This slope is derived from the inverse tangent of 20"-1.06" (x distance) divided into 20.85" (y distance), which you can find in Chapter 6. Gear Attach Bulkheads: The landing gear bulkheads are all on the same sheet. They can be cut from the specified foam in the plans without having to piece them together like F22 and the instrument panel. In addition, the hardpoints are available in a separate file. These need to be cut from the 22 ply BID layup. The landing gear bulkheads incorporate all of the modifications up to the current newsletter (4/95). You should delay drilling the clearance holes for the aileron rods until after the bulkheads are installed. Firewall: The firewall also includes all modifications up to the 4/95 newsletter. You will probably want to plot out two of these. One intact for cutting out the temporary firewall and another in pieces to cut up the 1/4" birch permanent firewall parts. The flared extensions off of the top side had curvatures were very difficult to match and there is about .050" of extra material around the inflection point that can be sanded down to shape to match the upper cowling more precisely.