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Oct 04, 2011
, 11:30 PM
Joined Aug 2004
OK, back to it. As I said before this is not a how to do it thread but some shots of important stuff along the way.
There is no difference in making a wing mold or a fuse mold. This is just the way I make my molds. After a couple of decades doing this you get a feel of what works for you.
I do not use Tooling Resin or Gel Coat anymore for the mold face. There was always the problem of chipping on the flange edge. I always use a razor blade to cut the seams and its easy to scratch the wax off losing the release. I now use straight epoxy (ProSet right now) with Milled Fibers mixed in to increase the strength around the edges where cutting will be done.
On the mold face itself I use resin with just a small amount of Milled Fibers in it to help it flow over the tool face. Generally I do two layers to have complete coverage.
The glass can be applied over the second coat when it has tacked up. I usually wait until the next day. It takes so long for it to go off I would rather do it late in the day and then leave it alone.
Normally I use 30 min hardener for these coats, but because its a one piece wing with dihedral I used the 15 min. so it wouldn't end up as a big pool at the center.
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This shot shows adding the Resin and Milled Fiber mix to the edges of the fuse mold. Same thing is done to the wing.
After the edge mix has set up the face coat is applied. This shows the second coat.