Looking real good Jeff.

so are you going to glass the plug frist?

Not planning on it, I’m hoping the release will make it pop out ok from the plaster.

it's going to be ruff ,you need to seal it with something pva wont work well on foam/spackel ,i would hate to see all the work on the plug messed up ...but if your not going to glass it why not just do it like John morgan does? or are you hopeing to get a few parts out of it . plaster type casts are good at picking up detail...what ever the plug looks like the mold will look like.

I'd definately add a layer of 6 oz. fiberglass to the plug, then it's on with the body filler and sanding, sanding and more sanding to get a nice smooth finish. This way you will have a much tougher and smoother surface. Should make it easier to get the plug to release from the cast as well I think as you can wax it in addition to using PVA.

your right if the surface is'nt glass smooth it wil be hard to release it .it just takes a lot of timr to do a cast ,or epoxy tooling .

Rodger / Arngeir,

I have a gallon of 2part epoxy used to encapsulate motor windings I was thinking of coating the foam with it. It is thin and would wick in to the foam pours and would make a hard shell to apply the body filler to. I’m going to try a test first to see if it will work.

might work ...i bet it is really hard to sand ...so just seal it with it ...the test piece is a good idea .

Wow, what a great project. Looks great

I think the epoxy will coat the foam ok, but it wont provide much protection from dents. I think you would want to throw at least a layer of glass on there to protect the foam from the hazards of the workshop

Are going to add the ROHR in-flight thrust reverser

Hi Jeff,
the plug looks great but I don't see the center boards we talked about. How are you planning on splitting the plug?

Dan Eaton

Dan,

I lightly glued the foam together at the halves. I will use mylar at the seam before I epoxy coat the foam so it doesn’t wick down the split. I will run a long blade and it should split easy. I would like to try some test before I tackle the fuse and wanted to know where you got the Hydrocal?

Hi Jeff,
You can get a 50 pound bag at Krueger's for around $25. They're located right off of I-44.

If you just want to experiment a little you can get a 1 or 2 ound box at Mark Twain for about half that.

Hey, I need to pick up another bag if you want to make a trip together. They're open late on Thursdays or during the day on Saturday but it'll be a zoo on Saturday.

Dan Eaton

Originally Posted by eatond

They're located right off of I-44.

Dan Eaton

Dan,

Making a trip south sounds good. I need to get Bob’s A7 gear back to you also; it helped to get ideas for mine. I’m also interested in your thoughts about the fuse and the plan.

...

plus one for the face coat ...only way to go for plaster