Aircraft - Electric - Airplanes
Scale Kit/Scratch Built
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Cut out the 1/2" plywood backers boards.
Right and left backers. Saw cuts on the edges mark former locations.
Cardboard templates used to rough cut foam before gluing to the backer boards.
Roughed blanks glued to backers with a gaps between to slide the templates in.
Slide the templates into the slots to check progress while sanding to shape. Wood spines screwed to backer to prevent bowing.
Taped and ready to bake.
Trimmed shell with formers marked.
Set up to mark reference line.
internal structure, ready to glue halves together.
Stabilizer cut out made and mocked up tail in place.
Set up for external linkage.
Tape removed, starting to sand out ripples.
Beech d-18 rudder linkage.
Rudder blanks. Hard to see but the hotwire is sitting on the two wooden blocks in the photo holding it above and parallel to the table. Just slide the blank through the wire to make the slices.
1/32" balsa reinforcement between the foam layers.
Recess for the stabilizer cut out after shaping.
Stabilizer core with flexible pushrod sheath in place.
Z bend that will go in horn in rudder.
Bellcrank with offset adjusters.
Bellcrank in place in stabilizer.
Opening in rudder. Bamboo skewer ties the top and bottom parts of the rudder together.
Ouch! This is what happens when foam is subjected to too high temps!
Replacement fuselage next to its roasted predecessor.
Ready to coat. Fuselage held in a cradle so I can rotate it while brushing on the Styrospray.
I squirt the mixed Styrospray using an old glue bottle; much easier to control how much goes on compared to applying with a brush.
Trying to show what the coated surface looks like here after the first coat.
Tail section fitted.
Cured SS from the inside of the applicator bottle.
Canopy area with film taped in place.
Film shrunk down tight.
Fiberglass applied and reference and cockpit outline transferred to the 'glass.
Trim off the excess 'glass. Note the nice smooth surface the shrink film leaves on the inside.
Support frame of FFF glued to the fiberglass.
Rear dam added and foam insert.
Insert installed and plaster poured.
finished plaster vacuform plug.
EPS blank attached to two boards with double sided tape. Top template in place.
Top cut made.
Rib locations marked and cut with hot wire. Stop blocks on the guide posts prevent cutting all the way through the EPS core.
Spar box slot cut.
Preform the $tree foam skin to approximate airfoil shape by rolling over a piece of pipe
Apply glue only to ribs, add skin, replace buck and weight down until Gorilla glue cures.
Make the cut for the bottom of the airfoil and remove the waste between ribs.
Cut hole and insert paper tube for ESC power wiring.
Glue in balsa sides of spar box. Spar stock slid between balsa sides (wrapped with a couple layers of packing tape) makes sure the slot stays the right width.
Add slot for servo wires. Masking tape is there to keep me from accidentally gluing the skin to the buck. Pull off the tape after the glue is applied and before the bottom skin is added.
Glue on the bottom skin (using the buck to clamp it place just like for the top skin) and trim the LE and TE with the hot wire after the glue cures.
Wing center section ready to glue on balsa LE and bamboo round on the TE.
Bamboo added to TE
Mark the cockpit and wing saddle.
Wing saddle cut out and faced with balsa. Good canopy with one of my unsuccessful attempts also shown.
Elevator servo mounted.
Cockpit framed out and cockpit "tub" shown.
Cockpit tub in place.
Plug half embedded in plaster.
Mold filled with silicone caulk/ corn starch mixture.
Finished mold and plug.
Clamp the mold halves together and pour in epoxy.
Seal the pouring end of the mold and rotate the mold overnight.
Pilot removed from mold and given a quick shot of primer. Weight is 6 grams.
Outer wing panel showing spar.
Spar scarf joint.
Wing tip blanks with bamboo reinforcement.
Nacelle form and shells.
Making the cut out for the wing in the nacelle.
Cutting jig and nacelle half.
Nacelle in position on wing.
Internal structure for the nacelle bottoms.
Top halves of the nacelles glued on.
Motors mounted, wires run, bottoms glued on.
Roughed out tip. Packing tape protects the nacelle shell while shaping.
Bamboo sticks are glued deeply into the foam to strengthen the tips.
Solid tip blended onto the nacelle shell.
Paper has been applied and small binder clips used the hold down the edges.
What it looks like when the WBPU has dried and the clips removed.
Excess paper trimmed off and any wrinkles sanded down.
SS coated nacelles and cowls.
Gluing on the top of the aileron to the shaped foam core.
Aileron shaped and hinge slots cut. Ready to round over the LE.
Cover glued on. Holes to access wing bolts.
Canon ports, lined with drinking straws, to duct air to the ESCs.
Other end of the ducts.
ESC cooling air exit port.
Pretty close to scale.......
Gun ports/air intakes
Squiggle and blotch camo test.
These seem smaller and tighter. Very fine spray settings.
RLM 75 splotches over RLM 76
RLM 76 squiggles over RLM 75
First attempt on some poster board.
Marking the wing. Mask and brush shown
The pattern is continuous over the wing saddle and onto the fuselage.
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