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Hover or die · 09:54 AM

I'm starting this thread for those interested in building their own intake ducts for their micro jet..
There are some real fiberglass masters on this site(AirSally comes to mind)but this is not needed to do a small project like this...maybe a little practice and patience though...
My plan is to cover every single step,with text and pictures..This will take a lot of the guesswork out of this project and allow more of you to build your own ducts..

I'm starting a micro scorpion and the ducts will be the focus of this thread..
Although there are many techniques to build ducts I feel like the way outlined here is pretty simple and within the grasp of most modelers..

This process will take a week to 10 days to finish so bare with me and we will get this project done...If you feel like anything is missed please let me know and I will add it to the first 3 post..

I'm going to start with some pics and will be filling in the text over the next few days as time allows...

Hover or die · Sep 26, 2012, 08:48 AM

Saved for pics and text

Hover or die · Sep 26, 2012, 08:49 AM

For pics and text 2

ksqm · Sep 27, 2012, 10:32 PM

Hover or Die,

There's been quite a few taking a peek. I guess once I get a set done, you'll have a lot more questions about your technique. I tried a short that didn't work, but I could see a set of ducts at 6g or lighter is within easy reach. Not much ventured, not much gained. Keep the pics comming. And good luck with the Viper maiden.

Ksqm

Freddie B · Oct 01, 2012, 05:11 PM

Mini-how-to's are so cool. Thanks and keep up the great posts.

Fred

Hover or die · Oct 04, 2012, 10:00 AM

Hey fellas,
Thank for stopping in...I have been a little under the weather over the last couple of days..With the little one n school it is like sending her to the germ pool daily for a dose of the bugs to bring home for mom and dad to tryout...lmao!

Chest colds go away relitively quick its just all the junk in your lungs that takes a month to finally go away..

OK,
I did finally get in there and fill in the text on the pics..
I plan to write the text up to the point f the pics today as well and should get back on the ducts tonight or tomorrow..

Thanks for being patient............Chris

Sep 26, 2012, 08:48 AM	#1
Hover or die it wasn't me flying that plane United States, NC, Wilmington Joined Mar 2011 697 Posts	Step by Step (Micro Composite Intake Ducts) I'm starting this thread for those interested in building their own intake ducts for their micro jet.. There are some real fiberglass masters on this site(AirSally comes to mind)but this is not needed to do a small project like this...maybe a little practice and patience though... My plan is to cover every single step,with text and pictures..This will take a lot of the guesswork out of this project and allow more of you to build your own ducts.. I'm starting a micro scorpion and the ducts will be the focus of this thread.. Although there are many techniques to build ducts I feel like the way outlined here is pretty simple and within the grasp of most modelers.. This process will take a week to 10 days to finish so bare with me and we will get this project done...If you feel like anything is missed please let me know and I will add it to the first 3 post.. I'm going to start with some pics and will be filling in the text over the next few days as time allows... Images View all Images in thread Views: 22 Pic #1. Drawing airframe to scale and drawing out intake ducts. Views: 20 Pic#2. Scale drawing of aircraft..Area of fan and intakes.. Views: 19 Pic#3. 1/16 plywood slid underneath for marking ducts for cutting general shape.. Views: 17 Pic#4. Plywood template to cut ducts from solid foam.. Views: 17 Pic#5. 1 cut and one marked for cutting 2nd template. Views: 19 Pic#6. Both templates set in the airframe to assure it is right.. Views: 20 Pic# 7. Marking the foam plug. Views: 17 Pic#8. Marking templates on the foam.. Views: 17 Pic #9..Having 2 metal straight edges will make things much easier..Wal-Mart,school/art supplies area.. Views: 18 Pic #10 .Marking to cut foam block to proper length Views: 17 Pic #11.Marking blocks for length cut.. Views: 17 Pic #12..I hold both metal rulers on the lines top and bottom and it makes perfect length cuts on your foam block.. Views: 17 Pic#13.. Hotwiring the length marks.. Views: 18 Pic#14..same cut showing how I hold the straight edges on top and bottom.. Views: 18 Pic #15..showing the nice clean cut.. Views: 17 Pic #16..cut to length and ready to move on.. Views: 18 Pic#17.wrapping the templates lines around to sides and bottom of block.. Views: 17 Pic #18 shot showing side marked.. Views: 17 Pic #19.. marking the bottom..you can see the other lines on the far side of the block to help line up perfectly.. Views: 19 Pic #20. Time to cut the plugs out using your 2 duct templates..1 on top and 1 on the bottom and squeeze tight for the wire...remember plywood templates have to be sanded really well along the edges so the hotwire slides freely without any hangups.. Views: 17 Pic#21. First cut is nice and smooth..time for the other side.. Views: 17 Pic #22. Now turn the plug around so you can cut the opposite side.. Views: 18 Pic #23. Hotwiring the other side.. Views: 18 Pic #24. Sides of plug complete..We still have to cut the height out but need to find our rise in the duct and mark it for the height cut. Views: 17 Pic #25. Time to cut the other side out..always remember to mark the front of the duct,on the templates and the foam plugs with an arrow. Views: 23 Pic #26. My little hotwire tool...very well worth the money...Works extremely well for all small stuff.. Views: 23 Pic#27. Basic tools for this job..Hobby knife,2 metal straight edges,pen/marker,hotwire tool.. Views: 17 Pic #28. Both plugs cut/and laid in airframe.. Views: 20 Pic #29.. Another shot of plugs..time to/mark the rise from intake to the fans face.. Views: 17 Pic #30. Mark those puppies.. Views: 21 Pic #31. This shows the thrust line for the viper..the fan must sit this high for a straight shot out the back..so this leaves quite a rise in the ducts and this must be marked and cut..Just a few steps. Views: 17 Pic #32. You need a bulkhead to except the rear of the ducts and marked for the intended fan..this allows you to mark the top and bottom of the plug according to the fans intended height in the airframe. Views: 17 Pic #33. Showing the plug marked at the rear. Views: 16 Pic #34. This shows the very small increase in height on the scorpion..will be cutting from nothing at the front(duct intake) to 3/16" in the back(where it meets the fan/bulkhead. Views: 17 Pic #35. My fan is 40 mm so I mark about41 mm at the front and 41 mm up from my bottom mark at the back of the plug.great thing about the metal rulers is they flex around small curves.. Views: 19 Pic #36. Side view showing plug marked for cutting the small rise and excess foam off the plug. Views: 17 Pic #37. Another view showing the back(fan)side of the plug..we have to wrap the marks all the way around both sides for straight, clean cuts.. Views: 18 Pic #38. Side marked and now to mark the backside of this plug. Views: 16 Pic #39 sides marked and lines marked for the backside.. Views: 15 Pic #40. Backside now marked and ready to be cut.. Views: 15 Pic #41. Carefully place straight edges on the bottom line top and bottom.. Views: 15 Pic #42. Get the rulers lined up well and/squeeze for the coming hotwire cut. Views: 24 Pic #43. I hold it like this fo these 2 cuts.. Views: 19 Pic #44. Making the top cut now..remember to remark your arrow on the side as you are getting ready to cut te top arrow mark off...lol
	Last edited by Hover or die; Oct 04, 2012 at 09:54 AM.

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Sep 26, 2012, 08:49 AM	#3
Hover or die it wasn't me flying that plane United States, NC, Wilmington Joined Mar 2011 697 Posts	For pics and text 2

Sep 27, 2012, 10:32 PM	#4
ksqm Registered User Hampton, VA Joined Mar 2009 1,044 Posts	Hover or Die, There's been quite a few taking a peek. I guess once I get a set done, you'll have a lot more questions about your technique. I tried a short that didn't work, but I could see a set of ducts at 6g or lighter is within easy reach. Not much ventured, not much gained. Keep the pics comming. And good luck with the Viper maiden. Ksqm

Oct 01, 2012, 05:11 PM	#5
Freddie B Addicted to building... Omaha Nebraska Joined Feb 2006 5,948 Posts	Mini-how-to's are so cool. Thanks and keep up the great posts. Fred

Oct 04, 2012, 10:00 AM	#6
Hover or die it wasn't me flying that plane United States, NC, Wilmington Joined Mar 2011 697 Posts	Hey fellas, Thank for stopping in...I have been a little under the weather over the last couple of days..With the little one n school it is like sending her to the germ pool daily for a dose of the bugs to bring home for mom and dad to tryout...lmao! Chest colds go away relitively quick its just all the junk in your lungs that takes a month to finally go away.. OK, I did finally get in there and fill in the text on the pics.. I plan to write the text up to the point f the pics today as well and should get back on the ducts tonight or tomorrow.. Thanks for being patient............Chris