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Old Dec 09, 2012, 12:21 AM
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Wings

Now more nights than I remember,
Did I bow to Glory’s charms.
Tonight My Lady smiles on me,
With bread in open arms.

Lo my world breaks open,
Dawning stairs that weren’t there,
Each step built with hand forged nails,
And dirty, unkempt hair.

Now steely arms spread open:
I have earned the right to fly.
The embers glow a quiet orange
As Glory casts my shadow on an ever sun filled sky.

- b1heqh54


...don't know how long this wing mould has taken me, but tonight it no longer matters...



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Old Dec 09, 2012, 06:14 AM
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Congrats... I feel and know your pain.
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Old Dec 10, 2012, 05:00 AM
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Merry Christmas to me...



Tomorrow we look inside.
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Old Dec 10, 2012, 08:12 PM
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I’ll fix the broken flange pretty quickly, but what you see is what you get. (prying with a screw still in place)

Everything worked out great !! (but I have some new ideas for next time…)

Enjoy the video.

IMG 7252 (1 min 0 sec)
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Old Dec 19, 2012, 12:05 PM
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All trimmed up, clean and waxed.

Here's a tip - keep your bench waxed up good.

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Old Dec 21, 2012, 08:09 AM
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A little dusty and a little worse for wear, I think I might just keep this plug hanging around like the hero it is....what a brave little soul

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Old Dec 21, 2012, 08:32 AM
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Good pics I keep all my plugs just in case. When will you be laying up parts? Looking forward.
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Old Dec 21, 2012, 10:04 PM
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This is the intended configuration of the lower tool during layup. As you can see, the leading edge will be integral with the lower skin. I will try one with a spar that straddles the joint between the upper skin and the leading edge. This may just be enough to make things nice and easy. If not, then I may later make joggle flanges to bolt to the lower section that would form a glue lip when the joggle flanges were removed prior to final assembly and I will move the spar rearward in the chord. I expect that I may have to vacuum bag the lower skin just to hold the cloth on the inverted mould face of the upper leading edges. Worst case they can always be layed up separately and joined to the lower skin while still a little green. If you look very closely you might see the LED's that I moulded into pockets recessed into the trailing edges at the ailerons. They are embedded proud of the tool face in a pocket designed to give the pushrod for the ailerons a place to exit the wing. This should provide nice lighting inside the tool during final assembly - cool or what...lol




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Old Jan 07, 2013, 05:28 PM
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Happy New Year Everyone !!

...and this year should prove to be an exceptional one

The most common question I get is how much detail do you lose.
My standard answer is don't breath on your plug while you brush on your tool coat.
Here's a few quik pics of the top of the wing mould.
This should ease your fears about losing any detail, but be warned I don't use PVA, only a thorough coat of pure carnauba wax.

Too many pictures you say - too bad








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Old Jan 07, 2013, 10:40 PM
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Here's a new idea...



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Old Jan 08, 2013, 08:21 AM
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Regards detail loss. All the molds I make have similar detail to yours. I also use canuba wax. The PVA I use is thinned slightly with water then air brushed on for a thin wet coat. Once dry it is only a few thousandths thick and hardly any loss of detail. I then pre-prime the mold then layup the parts for a superb finish.

Looking forward to seeing your build now that you have all the molds done. Congrats.
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Old Jan 08, 2013, 12:12 PM
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Upper Wing Skin #1

I wonder if I could introduce a two part pourable closed cell urethane foam into the brass fittings and get it to react slowly enough to avoid voids...maybe at a 2lb/ft^3 density. I've tried before with limited success, but first we'll try a simpler approach to see where we stand.







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Old Jan 10, 2013, 02:37 AM
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550 grams or 19.4 ounces or 1.2 lbs - room for improvement










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Old Jan 10, 2013, 07:45 AM
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I'm curious..... What weight of cloth and and layers used? What is the span? Thanks. BTW looking very nice.
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Old Jan 10, 2013, 01:23 PM
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