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Old Sep 03, 2014, 04:40 PM
2012 NZ Speedcup - 231 MPH
DownUnderPilot's Avatar
New Zealand, Tasman, Richmond
Joined Mar 2006
2,152 Posts
Build Log
Composite Fuse

Hi all,

Just wanted to share my success with making a fuse mould for my speedplane. It's approx 1.2M long and is designed for Speedcup style flying. I made the plug using 5mm MDF laminated together with coloured wood glue for ease of shaping.

The mould is made with a tooling coat using graphite powder and high density filler and ATH, and the backing is a poured layer of resin / ATH. This is a really fast way to make a mould!

Next is the h stab....

Dean.
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Last edited by DownUnderPilot; Sep 03, 2014 at 06:16 PM.
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Old Sep 03, 2014, 05:13 PM
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arcticflyer's Avatar
Canada, SK, Prince Albert
Joined Jan 2006
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If you produce any extras would be interested Looks good what will the overall specs be on the airframe?

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Old Sep 03, 2014, 05:20 PM
2012 NZ Speedcup - 231 MPH
DownUnderPilot's Avatar
New Zealand, Tasman, Richmond
Joined Mar 2006
2,152 Posts
Unlikely I'll be building extras at this point - it's a long way off before a completed airframe is ready I think.

The design is to allow 50mm spinner on the front, 40-XX outrunner or whatever else you can fit in there... Lipo carrying capacity will be up to approx 12S 3000. Wingspan is likely to be in the 1.6m area, T tail and wing saddle fillets for minimised drag. Wing 'foil is MH-54, tail airfoil is SD-8000.

Construction will be whatever is required I guess - I'm going to lay up a fibreglass trial and see how heavy/strong it is. I have "adequate" stocks or carbon and kevlar for improved strength / weight....
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Old Sep 03, 2014, 05:53 PM
Registered User
Hemet California
Joined Jul 2009
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Nice! you will really enjoy making your own

DE
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Old Sep 04, 2014, 10:19 AM
Carbon fiber is our friend
Steve C's Avatar
United States, CA, Lodi
Joined Feb 2001
4,257 Posts
Looks nice

How will you key the mold haves together? I don't see any holes or dimples.
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Old Sep 04, 2014, 03:24 PM
2012 NZ Speedcup - 231 MPH
DownUnderPilot's Avatar
New Zealand, Tasman, Richmond
Joined Mar 2006
2,152 Posts
Quote:
Originally Posted by Steve C View Post
Looks nice

How will you key the mold haves together? I don't see any holes or dimples.
I knew someone would ask!! - well spotted - actually they are there, on the right hand side - holes for dowels. Also the other half of the mould has a small flange that allows for positioning.

I'm attempting the first layup tonight, opinions please on the layup - would 48g/100g/200g/100g glass be sufficient? More? Less? It's a trial really to establish my technique and also determine if it would be strong enough.
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Old Sep 05, 2014, 02:15 AM
The Prop is Where its At!
blitzu's Avatar
New Zealand, Bay Of Plenty, Omokoroa
Joined Dec 2012
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Quote:
Originally Posted by arcticflyer View Post
If you produce any extras would be interested
Sorry Skip-Kiwi's first!
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Old Sep 05, 2014, 09:34 AM
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arcticflyer's Avatar
Canada, SK, Prince Albert
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Hey!....he needs a tester
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Old Sep 05, 2014, 10:58 AM
Caution:Makes sharp left turns
Troy's Avatar
United States, CA, Lake Forest
Joined Feb 1999
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Quote:
Originally Posted by DownUnderPilot View Post
and the backing is a poured layer of resin / ATH. This is a really fast way to make a mould!
What is ATH? Poraver, sand/silica, ....?
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Old Sep 05, 2014, 01:45 PM
2012 NZ Speedcup - 231 MPH
DownUnderPilot's Avatar
New Zealand, Tasman, Richmond
Joined Mar 2006
2,152 Posts
ATH is alumina trihydrate, it can be mixed with resin to create a really stable and strong mould backing. Du pont calls their version of it Corian, it's used for bench tops.

It's mixed to a consistency of runny honey and then you just pour!
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Old Sep 05, 2014, 03:14 PM
Aka: Tom Jenkins
ApexAero's Avatar
United States, FL, West Palm Beach
Joined Aug 2008
4,522 Posts
Beach Sand, plenty and free!
Dean, I'm getting practice on double layer winding!
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Old Sep 05, 2014, 03:24 PM
Caution:Makes sharp left turns
Troy's Avatar
United States, CA, Lake Forest
Joined Feb 1999
6,029 Posts
Quote:
Originally Posted by DownUnderPilot View Post
ATH is alumina trihydrate, it can be mixed with resin to create a really stable and strong mould backing. Du pont calls their version of it Corian, it's used for bench tops.

It's mixed to a consistency of runny honey and then you just pour!
Just got the scoop from our chemist... your mold is also very fire resistant now, too
I guess it's not as hard as silica so it might be considered less brittle as a highly filled system. It's also low cost, so good to learn something new today.
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Old Sep 05, 2014, 04:31 PM
2012 NZ Speedcup - 231 MPH
DownUnderPilot's Avatar
New Zealand, Tasman, Richmond
Joined Mar 2006
2,152 Posts
Quote:
Originally Posted by apexaero View Post
beach sand, plenty and free!
Dean, i'm getting practice on double layer winding!
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Old Sep 05, 2014, 05:37 PM
Registered User
Calgary, AB, Canada
Joined Oct 2002
1,936 Posts
Also seems to be getting some negative press with lengthened exposure to workers, so I guess exercise caution working with the raw powder.

http://www.nejm.org/doi/full/10.1056/NEJMc1404786

Just curious, does it react with the resin to increase exotherm temp, or would it be the same temp as any other typical silica type filler?
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Old Sep 05, 2014, 06:17 PM
Non Eius A Stupri Fucus
jackosmeister's Avatar
Auckland NZ
Joined Aug 2007
7,515 Posts
Looks badass DUP
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