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Old Nov 02, 2013, 01:00 AM
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Build Log
Building a new DLG fuselage mold

That's the result:





Normal version fuselage (~31-32 grams)



==New==
SL Fuselages (~26-26 grams)




And here's the build thread:

For a long time I wanted to build a new mold for my DLG's, recently I made some fuselage using my old mold and I was sick of it since it is full of cracks and it is hard to work on.
The new fuselage mold will have several different features that the old mold doesn't have:
1. The fuselage will be a bit wider (3-5 mm)
2. The wing saddle will be fluent and will fit most of the modern wings.
3. The elevator saddle that the old fuselage has built in will go
4. The new fuselage will have a mirror like finish!!

Making the master mold

I started of with my old fuselage to make the work a bit easier



Cut away the elevator saddle



Filled the gap with resin mixed with aerosil



The old fuselage's nose has to go as well...





To shape the new nose, I had to make a plug that is made of hard Rohacell (kind of a foam)





To make the fuselage wider, I glued some Rohacell strips on its sides to send it later to the shape I want



After some sanding, applying Car kit, more sand, more Car kit and on and on... The fuselage is starting to look like something...











There is plenty of work ahead of me until the master mold is done, but I promise that will be worth the wait...


Eitan.
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Last edited by eitanro; Apr 24, 2015 at 05:20 AM.
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Old Nov 02, 2013, 06:41 AM
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Hey Eitan,

good to see you're working on another project! Looking forward to your build log.

When I made the plug for my second mold I also used the boom of the old one and glued a chunk of MDF to it to shape the rest of the fuse. The joint wasn't strong enough and cracked during handling, I glued the two parts together again before making the mold, but now I have a tiny crackline in the female mold that imprints on every fuse that I make. So please make sure the glue joint is strong enough.


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Old Nov 02, 2013, 08:16 AM
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Thanks for the advise Jonas, I will make sure everything is properly glued..
I saw one of your fuselages you sold to a guy from Israel, it looks great! very strong!

Eitan.
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Old Nov 02, 2013, 02:17 PM
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in the process of making my own fuse , so i'll be following this with great interest

Dave
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Old Nov 04, 2013, 04:02 PM
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in the same process trying to learn more.
Go for it Eitan

Thanks
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Old Nov 05, 2013, 10:39 AM
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There have been a few threads documenting the process. IIRC, Jonas's thread was one of the good ones. I've got one out there as well.

Good luck!

Gerald
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Old Nov 05, 2013, 12:38 PM
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Thanks!

Some more progress today (looks little progress, but it takes forever...), the only thing I did today is: Bondo, sanding, Bondo, sanding and so on and on and on....
But the fuselage is finally starts to look like its closer to its finale shape, the only I'm quite happy with is the shape of the nose, it still looks like a Dil#&











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Old Nov 05, 2013, 03:24 PM
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Well done! looks like clean and accurate work.

Jonas
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Old Nov 12, 2013, 05:21 PM
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Old Nov 12, 2013, 09:25 PM
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What jarhead said
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Old Nov 12, 2013, 10:33 PM
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didn't had much progress yet. I will update the thread next week when I will continue the build...
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Old Nov 21, 2013, 01:36 PM
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Finally had some time to build the master mold, after many many sanding and lots of bondo, I thought that I got the final shape, but it looked to narrow





In order to prevent the bondo to crack (there is a lot of bondo!), I used some FG to reinforce the master mold









After the resin cured, I piled the pill ply



After consulting with some friends about the nose shape, I changed it again... The 2 main changes are:
1. The nose is a bit wider.
2. I did a small down angle to the nose tip (barley seen)







And finally I painted the master mold with a primer\filler paint!

Top side view



Side view



Bottom view



Hopefully the next time I will update the thread, I will have the master mold finished.

Eitan.
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Old Nov 21, 2013, 02:16 PM
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Too narrow depends on what you want to achieve. My fuselage is just over 7/8" wide at the widest and just under 1 3/8" tall at the tallest. There is no problem putting a pair of RJ DS285 or equivalent inline in the fuselage, with battery, and various receivers with case.

What are your dimensions?

Gerald
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Old Nov 21, 2013, 11:42 PM
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I have not taken measurements of the fuselage (I kinda sculpture is as I go along), but it was a bit narrower than 7/8"...
A KAN 400 mah battery with a 1-2-1 configuration (----======----) would barely fit in and its cell diameter is only 0.4", the battery pack (with a single cell at the front) ended about 1" from the nose tip, Futaba R6106HFC receiver would have been very tight in there.
Many people will find it to hard to fit radio gear inside a narrow fuselage and since I do intend to sell some of them, I have to take that in account.
Eitan
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Old Nov 22, 2013, 12:53 PM
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More progress today... I sanded the primer paint to smooth it out, several pin holes were reviled, so I used a filler paste (made by Sikkens) to seal them:







After filling all of the pinholes, I started painting the master mold.
Start with a lite fogy layer and then added another 4-5 thicker layers.









But as always happens, Murphy intervened and more pinholes were reviled





The next step is to seal the newly relieved pinholes and paint it again, after that I will polish it.

Eitan.
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