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Old Mar 21, 2015, 08:37 AM
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Build Log
Replacement Carbon Wing Build

Hi, Iíve been thinking about this for a while but now Iím ready to build a replacement (hopefully upgraded) wing for my Supergee / Blaster hybrid DLG.

A bit of info about the glider first. I originally built this DLG back in 2012. It uses a standard Supergee II wing with a lay up of two layers of 25 gsm fibreglass (140g). The fuselage is 4 servos in the pod using a bought carbon fibre tail boom with the servos mounted to a carbon fibre covered balsa insert glued in to the tail boom. The pod is non structural and moulded from 100gms Kevlar cloth very similar to the Blaster 3. The tail is completely Blaster 3 bought from Hyperflightís spares section including the V mount. The servos are SD150ís on Flaperons and 2x SD100ís on Elevator and Rudder. All up weight is 285g.

This glider has served me very well but now the wing is looking a bit knocked about with many dents on the top surface mainly from catching. Therefore I now want to build a full carbon fibre version using the Zone V2 foils. I also want to document the build so I can try and put everything in one place to help others easily (As well as serving as a reference for myself). I especially want to help those in the UK with sourcing materials etc so I will try and link suppliers etc.
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Old Mar 21, 2015, 09:55 AM
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Getting Started

Foam Cutting.

Ok to get started. I downloaded and printed the Zone V2 templates from:

http://www.rcgroups.com/forums/showthread.php?t=1348570

This is going to be a 4 panel (2 Panels per side) wing.

I stuck the 6 x printouts to some thin Formica sheet (Could use plywood) and cut out slightly oversize using a new razor blade. The template was then finished to size using a file and progressively fine sand paper. The top and bottom templates were then accurately laid on top of each other and drilled through 1.6mm in four places to accept the pop rivets that will hold the template to the foam during cutting.

Next the foam itself. The only foam I can get a hold in the easily in the UK is this.

http://www.space-insulation.com/prod...ace-board-eco/

It is 30PSi and held up reasonably well on the previous wing and cuts really nicely so I will use it again. Wickes and B&Q used to sell it as individual 1200x600x60 mm panels.

Next I drew some blocking out templates in AutoCAD. I will add these files when I go back to work on Monday. The template allows the foam to be easily marked up. The Inner and Tip foam blanks were then cut to the marks using vertical wooden guides clamped to my work bench.

Two parallel lengths of 25mm Formica strips were cut and drilled. These are used to cut the 60mm thick foam blank into 2 x 25mm blanks. Its best to cut both top and bottom of the foam or it will not stay flat.

To be continued....
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Last edited by Iain78; Mar 23, 2015 at 09:26 AM. Reason: Template File Added
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Old Mar 22, 2015, 05:50 PM
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Joining and Sanding

A bit more progress. Wing panels and beds joined using 3M77. I get it from Cromwell tools.

https://www.cromwell.co.uk/MMM8021050K

Panels joined, Tips cut and sanded.
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Last edited by Iain78; Mar 23, 2015 at 09:30 AM.
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Old Mar 22, 2015, 06:35 PM
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If you want to make the wing a little prettier and possibly very slightly better, I have a suggestion. http://www.rcgroups.com/forums/showp...&postcount=450 That's what Phil and I did with our bagged wings.

Gerald
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Old Mar 22, 2015, 07:32 PM
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Thanks Gerald. That's is a clever technique which will smooth the transition between the panels. I'll give it a go on the other wing. Next time I'll also try more panels but this is is only my second wing so I'm trying to keep it as simple as possible.
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Old Mar 22, 2015, 09:32 PM
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More panels is a bit more work and in theory only yields a little extra performance. But I think in practice it yields a more noticable difference due to the reduced wire lag leading to more accurate panels. In any event, keep up the good work!

Gerald
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Old Mar 23, 2015, 04:55 PM
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Spars

I'm using Jonas M. style spars using 3 x 0.5mm carbon strips. I got them from Hyperflight.

http://www.hyperflight.co.uk/product...m-carbon-strip

I'm however adding a vertical shear web (Supergee II style) to the bottom spar made from the same 3 mm carbon strip.

The epoxy I'm using throughout the build is West 105 with 206 slow hardener from East Coast Fiberglass.

http://www.ecfibreglasssupplies.co.u...acks-12kg.aspx

I'm also using Ca-O-Sil to thicken the Epoxy as required.

http://www.ecfibreglasssupplies.co.u...ed-silica.aspx

Ok here we go.
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Old Mar 23, 2015, 05:11 PM
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Tbh I found west systems dried a little "soft" is the best description I can come up with. The stuff from easy composites seems to a lot tougher.

I've also built wings from this foam and has proved sturdy enough on my proto1, if. A little grainy,however I now use a foam supplier in the uk ( took me while to find) I'll add the link as soon as I can get to a pc but they do different types , colours and weights.

Dave h
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Old Mar 23, 2015, 05:42 PM
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Thanks Dave, I would welcome some help as far as foam is concerned. I've tried but could not find any foam other than the stuff I am using. I'm always reading that 40 to 60 psi would be better so I would appreciate a link to a supplier.

Did you cure the west epoxy in a hot box? I found this makes for a tougher result if it sets at a temp of about 40 deg C.

I'll need some more Epoxy soon so next time I think I'll try a different brand. Is this the stuff you use?

http://www.easycomposites.co.uk/prod...ing-resin.aspx

Thanks for the help.
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Old Mar 23, 2015, 05:51 PM
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West System's epoxy is really somewhat unsuited for the job. It has a very low glass transition temperature, Tg, such that it becomes flexible just sitting out on a hot sunny day (or can, depending on where you live). It has too high a viscosity, tacks too fast, etc, to allow good wetout and resin content control in a layup. It is also tacky to start with which makes handling some fabrics trickier as a roller passing over them will tend to pull the fabric up a little which pumps air into the layup which is not a good thing.

If one is doing wood construction boatbuilding then West is awsome. It isn't super rigid, will adjust some to conform to the wood due to low Tg on hot days, is flexible enough not to crack when the wood bends... Tackness helps laying fabric up on vertical or near vertical surfaces. But for aero work it is not suitable.

I use MGS 285/286/287 system. In your neck of the woods, R&G in Germany should carry it. There are other choices which are good but I think MGS is the best. Unfortunately, also rather pricy. Advantages of MGS is full cure at room temperature is possible, Tg is fairly high for a room temp cure, it isn't tacky, it is watery for good wetout and resin control, has low odor, has a bit less toxicity than many epoxies, and the color is clear with a very slight blue tint and the color is UV stable so it doesn't yellow on sunlight exposure. Tg also goes higher with a moderately low temperature post cure of perhaps 120 degrees F which is fairly easy to achieve.

Gerald
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Old Mar 23, 2015, 06:45 PM
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Thanks Gerald, It looks like I need to get some different Epoxy!

However West held up fairly well on my previous wing and there's not a great danger of it getting too hot here in the North of England! However I agree it is rather tacky to apply and de-bulk. Again it was down to what I could get locally.

I'll see what I can get my hands on before laminating.
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Old Mar 24, 2015, 06:25 PM
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Leading Edge

Wing came out of the bag and is now nice and stiff thanks to the spars. I'm fairly pleased with the way the spars came out.

Next make some leading edge material and apply. I have used 1 layer of 100gsm Kevlar on the bias followed by 2 x layers of 25gsm of glassfibre also bias cut. The glassfibre will allow for some sanding without touching the Kevlar. The material is stuck to the leading edge using transfer tape. Here is a list of materials used:

http://www.ecfibreglasssupplies.co.u...-1-m-wide.aspx

http://www.ecfibreglasssupplies.co.u...-mtr-wide.aspx

http://www.ukindustrialtapes.co.uk/a...-atg-tape-12mm

and I used these scissors to cut the Kevlar

http://uk.rs-online.com/web/p/scissors/0487135/
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Old Mar 24, 2015, 07:04 PM
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Oh forgot to mention that I'm going with this resin.

http://svsponline.co.uk/Scheufler-L285-resin.html

Thanks for the advice.
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Old Mar 24, 2015, 07:48 PM
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Try to get a hardener to aim for a decent potlife. I like my 120minute 386 so i can make a mess of my layup, correct it and still get a good part
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