Thread: Build Log Dornier Do-335
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Old Jun 11, 2011, 04:07 PM
pmullen503 is offline
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United States, WI, Fond du Lac
Joined Sep 2008
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I'm going to use a formed FFF fuselage. The method was originally developed by Harpye. I'll use a solid form and do the forming in an oven but otherwise the method is the same. It's light, strong and really a time saver if you plan to do multiple copies. Using a solid form allows me to do this with little more than a scaled up three view.

J Morgan graciously sent the form he used for his fiberglass Do-335 which I had hoped I could use but I decided to make a new one from scratch. Having John's form there a guide while I was shaping mine was a great help.

The methods I used are described here and here but the steps are:
1. Trace the side view onto a pair of 1/2" plywood backer boards.
2. Use the cross section from the blown up 3-view to make templates to rough cut the fuselage sections about 1/4" over sized.
3. Glue the rough cut sections to the backer boards and sand to the final shape using the templates to check progress and make sure both sides match. I make hot wire cuts in the sanded form and trace the outline onto cardboard for areas where there will be structure but no cross section on the three-view.
4. I covered the form with fiberglass and epoxy for durability. It's not strictly necessary if you only plan to pull a couple copies.
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