|Jul 30, 2010, 10:06 AM|
Thanks for that...
I may just not have!
I'll get to the polishing bit this weekend!
Hey, look Adam...
A new polishing tool!
It may appear as if I don't listen very well...
But, I do ponder these things!
|Jul 31, 2010, 01:02 PM|
It's a dish washing foam scrubber!
That's what was lying about.
Alternatively, I could cut my wife's cushions open!!!
|Jul 31, 2010, 01:06 PM|
Joined Feb 2007
nice canopy cutout Johann... did you use a bandsaw to do it? Looks like you got a nice symmetric result.
I'm in the midst of trying to finish my Strega.. my Sally mold is taunting me from the shelf.
|Jul 31, 2010, 01:29 PM|
Well it's almost done...
A few more wax layers, and we can move on!
The mould is looking great!
Something about looking at your new born.....
|Jul 31, 2010, 01:54 PM|
I have a similar one on the bench,
It needs repairing after a bad tumble!!!
It's just not the same....
and a whole list more!
I cut the canopy with a dremel cutting blade and made good with a dremel sanding disk!
(difficult angles... Still trying to get rid of all the sanding dust!)
|Jul 31, 2010, 02:40 PM|
Phenomenal Job!!! Looking better and better every time you post Johann. That fuse mold could almost do double duty as a shorty paddle with its shape. How did that DIY buffing disk work out for you, worth the effort?
I also was wondering how you got such a nice systematical cut (I still haven't cut into my canopy mold because I don't really know how to make a symmetrical cut or draw one for that matter).
|Jul 31, 2010, 03:55 PM|
He describes it better than I..
That's what inspired me to do my first mould!
I was to scared to cut the mould, but it's not a big issue, and will make your life a lot easier...
I battled trying to do internal seams...
Once you have the canopy opening...
It's a piece of cake!
|Jul 31, 2010, 05:34 PM|
|Jul 31, 2010, 10:52 PM|
And now for something completely different...
So far, Johan's mold is amazing -- a thing of beauty. I can't wait to see how it works out.
I'm still working on the "poor man's Sally". A few practice pods behind me, it's time to start on the real thing.
Disclaimer: This is the first time I've worked on a lost foam pod, and my fiberglass experience is similarly limited. You can probably learn more from my mistakes than my knowledge.
The sleeve material I'm using is 1.5" Carbon/FGlass hybrid woven sleeve material from Soller Composites http://www.sollercomposites.com. After shaping the foam pod [and cutting the wing-cutout before shaping (thanks for that tip, Steve)], I inserted some coroplast and foam into the wing cutout so that the compression of the sleeve didn't distort the pod. I used two layers of the sleeve, drying and trimming the first layer before applying the second. Then topcoated with another layer of epoxy. The nose shows some crimps from the cable tie that I used, but hey, this is a Sally, not a hotliner. I opted to leave them rather than compromising the strength of the nose -- the way I land, the nose needs all its strength.
Let it set up in my cool damp basement (hey, it's summer here) and then completed the cure for 24 hours in my oven in the kitchen, which has a "bread raising" setting of 100 degrees F, perfect for epoxy!
I then used my Dremel Multimax tool to trim the end and the wing-cutout. I originally bought this tool to trim some woodwork for my ceramic floor. It cuts with a vibrating motion and not a spinning blade, so it worked really well for the curves of the wing-cutout. The coroplast worked well to help to define the edge of the cutout as I was trimming the fiberglass.
Once trimmed up, I sawed the pod in half, as Steve suggested, and then melted the foam. Came out clean and nice, with a weight of the pod shell of 32.7g.
More to come...
|Aug 01, 2010, 12:38 AM|
Looking great! that sock looks well posh
Lost foam isnt a poor mans approach, its just different. You get quick results, its easy, has very little cost involved and isnt labour intensive... the perfect solution for us guys building the odd plane now and again.
If you're building a whole squadron like our Joan then a mould is worth the time and investment.
Keep it up!
I hope alls well down south, not alot going on in grey cornwall at the moment, I seem to have angered the wind gods
Your mould is looking top notch, you're getting good at this lark aint ya , cant wait to see the first fuz pulled.
take it easy
|Aug 01, 2010, 09:54 AM|
Thanks, Steve. So the pod's almost complete -- gotta think about the wing.
Steve, did you bag two halves separately and then fg them together, or did you glue the foam and bag it as a complete wing?
Any structural additions, except what's listed on posting #1 as a couple of CF tows?
|Aug 01, 2010, 10:02 AM|
I bag the wing as one, its the best way all round.
I only added the carbon tows and 200g glass leading edge.
If you're going light weight you dont need anything extra, in fact I doubt I needed the carbon tows!
|Aug 01, 2010, 11:08 AM|
I think we share the same wizard as regards wind!!!
It's been all in directions lately (mostly the wrong direction)
If any at all!
But there is hope.....
Our windy season starts in September!
The Sally's are looking great!
I like your pod Dave!
|Aug 01, 2010, 04:41 PM|
Did not go that well..
Difficult corners and steep narrow sides!
I also tried a new epoxy resin that flashed off halfway..
I think it may work.
The layup is very light with:
Splooge in the corners
1x50g veil cloth
Odd bits were used to reinforce the canopy lip, tail and shoulder areas.
With such a thin lay-up, I'm a bit concerned getting it out of the mould in one piece, as the first ones tend to "stick" a bit!
I'm just waiting for it to cure a bit before trimming...
I'll spray Daron's Wasabi fuse whilst I wait...
(my favorite job)
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