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Old Jul 30, 2010, 11:06 AM
Stirring the pot
johannlochner's Avatar
Port Elizabeth South Africa
Joined Jun 2008
4,023 Posts
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!
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Old Jul 30, 2010, 11:10 AM
Just fly it!
wyowindworks's Avatar
Cody, WY
Joined Nov 2007
6,915 Posts
That a very stylish green!

Adam
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Old Jul 31, 2010, 02:02 PM
Stirring the pot
johannlochner's Avatar
Port Elizabeth South Africa
Joined Jun 2008
4,023 Posts
Quote:
Originally Posted by wyowindworks View Post
That a very stylish green!

Adam
Not sure about stylish....
It's a dish washing foam scrubber!
That's what was lying about.
Alternatively, I could cut my wife's cushions open!!!
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Old Jul 31, 2010, 02:06 PM
Registered User
United States, CA, Berkeley
Joined Feb 2007
1,276 Posts
band saw?

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.

soon...



Ben
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Old Jul 31, 2010, 02:29 PM
Stirring the pot
johannlochner's Avatar
Port Elizabeth South Africa
Joined Jun 2008
4,023 Posts
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.....
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Last edited by johannlochner; Jul 31, 2010 at 02:47 PM.
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Old Jul 31, 2010, 02:54 PM
Stirring the pot
johannlochner's Avatar
Port Elizabeth South Africa
Joined Jun 2008
4,023 Posts
Quote:
Originally Posted by skinnydoc View Post
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.

soon...
Ben
hey Ben, you are gonna love that plane!!
I have a similar one on the bench,
But....
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!)
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Old Jul 31, 2010, 03:40 PM
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alexhaben's Avatar
Eureka, CA
Joined Nov 2008
429 Posts
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).
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Old Jul 31, 2010, 04:55 PM
Stirring the pot
johannlochner's Avatar
Port Elizabeth South Africa
Joined Jun 2008
4,023 Posts
Quote:
Originally Posted by alexhaben View Post
How did that DIY buffing disk work out for you, worth the effort?
For sure!
It's no trouble at all...
Just gives it that extra shine thas even fine sanding won't!


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).
Try reading Samotage's Jart build thread....( back in 2006)
He describes it better than I..
Epic thread!


http://www.rcgroups.com/forums/showt...motage&page=38

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!
Good luck!
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Old Jul 31, 2010, 06:34 PM
Entropy is happening!
Jim.Thompson's Avatar
Australia, NSW, Bellingen
Joined Aug 2008
7,311 Posts
Quote:
Originally Posted by alexhaben View Post
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).
I don't either Alex!

Jim.
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Old Jul 31, 2010, 11:52 PM
Building with TLAR precision
Zenmaniac's Avatar
near Madison, WI
Joined Jan 2009
2,757 Posts
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...

-= Dave
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Last edited by Zenmaniac; Aug 01, 2010 at 12:12 AM.
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Old Aug 01, 2010, 01:38 AM
Fly fast, Dont crash.
Thepasty's Avatar
Cornwall, UK
Joined Sep 2006
2,459 Posts
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!



Joan,

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

Steve
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Old Aug 01, 2010, 10:54 AM
Building with TLAR precision
Zenmaniac's Avatar
near Madison, WI
Joined Jan 2009
2,757 Posts
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?

TY.

-= Dave
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Old Aug 01, 2010, 11:02 AM
Fly fast, Dont crash.
Thepasty's Avatar
Cornwall, UK
Joined Sep 2006
2,459 Posts
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!
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Old Aug 01, 2010, 12:08 PM
Stirring the pot
johannlochner's Avatar
Port Elizabeth South Africa
Joined Jun 2008
4,023 Posts
Hey Steve
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!
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Old Aug 01, 2010, 05:41 PM
Stirring the pot
johannlochner's Avatar
Port Elizabeth South Africa
Joined Jun 2008
4,023 Posts
First casting!
Urmmm....
Did not go that well..
Difficult corners and steep narrow sides!
I also tried a new epoxy resin that flashed off halfway..
But
I think it may work.
The layup is very light with:
Splooge in the corners
1x50g veil cloth
1x86g cloth
1x50g
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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