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Old Mar 09, 2016, 12:15 PM
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My first compression molding wings

Thought I would share with ya'll what I am doing with my Corian Molds and trying to build DLG wings in a compression mold.

I have had a few problems with the molds along the way that required reworking especially in the parting plane area. I am creeping up on success slowly but surely.

These are 160mm root chord, high aspect wings, Rohacell foam, hardened leading edge. I had already built a few sets of these first bagged, and then top molded and bagged bottom to see if I liked the way it fly's, and I do a LOT.

Launches high, runs fast and returns home well, thermals and slows down nicely.

So the say a picture is worth a thousand word, here are the pix.

Terry
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Old Mar 09, 2016, 12:16 PM
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Trimmed wing weighed 55g

Terry
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Old Mar 09, 2016, 01:26 PM
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Excellent work Terry.
Yuri
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Old Mar 09, 2016, 01:30 PM
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Nice Terry. Very nice.

I love seeing these pics pop up.
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Old Mar 09, 2016, 01:49 PM
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Thanks for sharing!
wish I had a mill available, all these beautiful build projects are making envious
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Old Mar 09, 2016, 03:13 PM
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Beautiful, man. Just awesome.
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Old Mar 09, 2016, 03:49 PM
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Guys, I appreciate the positive comments, especially from someone like Tom, who was an inspiration for me to continue when I had failures. The other inspiration when I knew I had to do a lot of hand work on the molds was watching a video titled Formula 1 Turbo Engines The Golden Era [ Documentary]
Formula 1 Turbo Engines The Golden Era [ Documentary] (2 hr 53 min 21 sec)
. After watching those artisans hand carving plug tooling (at 28 min) for F1 heads out of wood (CNC was to expensive back then, man have we come a long way)I figured I could do the hand work I needed to on these molds.
It's been a while coming and I made a LOT of mistakes getting to this point. As those of you who have done this know, getting to this point the first time is a pretty steep hill to climb, or at least it was for me. My CNC machine with care can cut some pretty nice cores, but cutting the molds on it was a mistake, and required a lot of hand work to get them to this point. It has to be a labor of love.

But on the positive side the test wing flys very nice. I have a Vibe (just a fantastic plane!) and a Snipe (also good) to compare it to and for me I think it's right up there.

Terry
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Old Mar 09, 2016, 03:51 PM
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Man am I tired of sanding!!

Terry
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Old Mar 09, 2016, 04:31 PM
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Quote:
Originally Posted by Chuchuf View Post
Man am I tired of sanding!!

Terry
Ha, yeah; so true... End product looks fantastic Terry.
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Old Mar 09, 2016, 08:53 PM
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It looks really good Terry!

Sanding, oh the sanding...

Mind sharing what your blank Rohacell weights were? Type of paint used?

Fyi my blank XPS 25 core weights are 40g. Blank Rohacell IGF31 are 58g. That's for a pair milled 0.040" oversized.
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Old Mar 10, 2016, 11:02 AM
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Very nice Terry!

Mind sharing some of the details of the Zyvax? PVA releases great but is such a pain to mask for paint, yours' look fantastic.

Thanks, Rj
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Old Mar 10, 2016, 01:53 PM
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I haven't used the Zyvax but have some samples on order following Terrys success, and actually Graham (Storm) mentioned it a few years ago. I also have Partall High-Temp wax which is Teflon based and in theory you can spray directly on that (not sure how the release with IMC will go on that, but I suspect it will be similar to dolphin wax+paint).

For the Zyvax, I ordered the Waterclean to clean off my molds from any previous release agent, the Sealer GP and Zyvax Flex-Z 4.0 and 6.0. My big concern is longevity once the can is open, for any semi-perm.

http://www.chemtrend.com/our_brands/...release_agents
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Old Mar 10, 2016, 02:10 PM
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I use 3 and 4. Using the 6.0 may be okay for unpainted stuff, but I suspect even then you may have trouble keeping stuff in place while closing the molds.
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Old Mar 10, 2016, 02:42 PM
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Good to know Tom. I was wondering what the downside was to the higher slip.

Any comments on shelf life? Does it go bad after a few months? Suddenly expire after some hot/cold/hot cycle?
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Old Mar 10, 2016, 02:44 PM
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My other questions for molding these days, besides core weight are:

1) How are you applying the paint? I'm looking at air brushes now and that is a whole nother world to get into...
2) What clear coats (specific) have you used with good effect?
3) Masking?
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