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Old Apr 25, 2013, 01:26 AM
flying in the rain....
dave_beardsley's Avatar
Snohomish, WA
Joined Jan 2002
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Maple Leaf Design's Royale F3J

Hi all -

I'm throwing up some photos showing the process we went through coming up with the new F3J model from Maple Leaf Design.

I'd planned to do this a few nights ago, but have been slammed with some new CAD work.... go figure... I hate it when it gets busy!

Please feel free to ask any questions. There are a ton of images. I'll start with this set tonight, then follow up with more ASAP.
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Old Apr 25, 2013, 01:34 AM
flying in the rain....
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Snohomish, WA
Joined Jan 2002
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these are broken down from the folders used to drive my SASS club presentation. I'm just dumping each folder full of images. Some may not be super clear without an explanation.

The first set is the build
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Old Apr 25, 2013, 01:42 AM
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Snohomish, WA
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Early Foam Proto's
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Old Apr 25, 2013, 01:49 AM
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Snohomish, WA
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Tips
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Old Apr 25, 2013, 01:49 AM
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Snohomish, WA
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Shipping
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Old Apr 25, 2013, 01:58 AM
flying in the rain....
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Snohomish, WA
Joined Jan 2002
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some of the latest images as the production tools were completed and production models are in process....
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Old Apr 25, 2013, 02:25 AM
ETS....Energy retention system
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gold coast australia
Joined Aug 2008
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Wow.... Very nice work Dave.

So many questions..

Tim
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Old Apr 25, 2013, 10:21 AM
Challenge is rewarding
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San Diego, CA
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Nerdgasm
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Old Apr 25, 2013, 10:44 AM
Sherpa
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La Quinta, Ca.
Joined Sep 2003
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This is great. Is the plug material Corian?
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Old Apr 25, 2013, 10:48 AM
Composites guy
North OC, Ca.
Joined Jun 2005
1,177 Posts
And folks wonder why nice planes cost money.

Quality tools, quality parts.

Did you seal the tools or add a release system or is that Don's job?

On the wing tools, I assume..., that the composite tool was an early tool? the tool looks like a thich lay-up but I did not see much back-up structure to keep the tool warp-free and stiff. Overkill? I have seen several wing molds warp or get abused.

Say hi to Don for me.
Cheers
Scott
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Old Apr 26, 2013, 01:45 AM
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Snohomish, WA
Joined Jan 2002
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We cut just about every type of material my machine would take.

For a majority of the parts, we ended up going with a material called KKR. Its a modified solid surface material (similar to Corian). A compressed cast acrylic, with a higher mineral filler content, bonded with UPR and PMMA.

Just about every step of the way this project was a learning experience. Just the test cuts and material selection seem to take forever. The good news is, we cut it all, and I'm confident we arrived at the best choice based on all the constraints.

Since these parts were made I've got a bunch of other parts with the same material. Its great stuff!

Dave
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