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Apr 06, 2010, 05:19 AM
Registered User
Chris,

Use solarfilm.

Wrap the Mandrel in paper towel, about the same thickness as your cloth, a little bit bigger would be good.

Wrap solarfilm around that with the sticky side facing out, Iron the join together with oven bake paper so it doesnt stick to the iron.

Wrap the mandrel in wet cloth, slid on the solarfilm and then heat shrink.
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Apr 06, 2010, 05:28 AM
Thermal Wrangler
DrFragnasty's Avatar
Thought about that a while back but didn't pursue it. Worth a try Mike. Why sticky side out though...?
Apr 06, 2010, 10:55 PM
Registered User
Quote:
Originally Posted by DrFragnasty
Thought about that a while back but didn't pursue it. Worth a try Mike. Why sticky side out though...?
G'day Chris, have you ever had to recover a model? Peeling off solarfilm is a pain in the but the colour sticks no good stuck to your nice new pretty boom the shinney side will release better.

Looking forward to seeing the fruits of your labour at Jerilderie, which once again is just around the corner. Have you guys laid up any new nexor wings yet?

cheers Brad
Apr 07, 2010, 02:56 AM
Registered User
Brad answered it for you.
Apr 07, 2010, 08:24 AM
Thermal Wrangler
DrFragnasty's Avatar

solarfilm as bagging device


That makes sense, cheers Brad.

As for the wings, won't be too far away. How's your Jerilderie weapon coming along?
Apr 08, 2010, 10:00 AM
Registered User
Quote:
Originally Posted by DrFragnasty
That makes sense, cheers Brad.

As for the wings, won't be too far away. How's your Jerilderie weapon coming along?
Hey Chris, we need to pull the finger out if they are to be used in anger at Jerilderie. Everything in life seems to take time! But lots of fun which is the main thing.
Jul 03, 2010, 03:35 AM
Thermal Wrangler
DrFragnasty's Avatar

Nexor Pro progress


Just an FYI,

Nexor Pro project is coming along. Not glacial progress anymore now Team Machine is back from Jerilderie.

The rude shape nose plugs are mdf infused (OK, brushed-on but infused sounds more dramatic) with Evadure; expensive but penetrates the MDF deeply (5mm approx).

After it's gone-off, a bit of 600 grit and the plugs could be waxed ready for the mold.

The mandrel and mandrel rotisserie is Steve's impeccable work. It'll make doing the lay-ups so much easier.

That's all folks!

Chris.
Jul 25, 2010, 03:25 AM
Thermal Wrangler
DrFragnasty's Avatar

FYI WIP Postcard from Tassie


Bruce, Steve & YT spent a couple of hrs today prepping the molds then laying down some paint.

The original wing mold used no centre-panel dihedral so we modified it to provide more hands-off stability.

Cutting and securing the molds at the right angle required a bit of work to maintain alignment and the subsequent filling at the root junction needed a bit of elbow grease (Stephen's forte).Then finished-off with wet n' dry 600-800-1200-polishing compound.

5 coats of wax later and it was ready for masking.

Underside has a few stripes with a width based on A4 paper. Alternating white and Lamborghini Balboni Grey. The top is all white. Paint is 2-pak DuPont and sets really quickly.

This week I'll cut some fabrics ready for an all-day lay-up session next weekend.

Stephen is making inroads in the layup for the boom. Soller Composites have a wide-range of hybrid sock in red/ yellow/ blue. Heat shrink worked well to compress it onto the mandrel and the end-result is a mechanically optimum layup (no seams). The layup is carbon uni and the hybrid sock. The genius is in how the uni is applied so there's reinfoircement where it's need most (wing root and tail root).

Chris.
Last edited by DrFragnasty; Jul 25, 2010 at 03:32 AM.
Jul 26, 2010, 02:23 AM
Thermal Wrangler
DrFragnasty's Avatar

layup


Wing layup is bog standard:

paint (2K white tops, grey/white bottoms)
3/4oz plain 'glass on bias
1mm balsa
93g plain weave carbon
3/4oz inner 'glass

Can of el-cheapo hairspray to give the light fabrics some temporary "body" while handling/cutting and to smell nice and keep my 'fro in order.
Jul 26, 2010, 03:44 AM
Detail Freak
target's Avatar
Carbon on the outside right Chris?
Jul 26, 2010, 05:18 AM
Thermal Wrangler
DrFragnasty's Avatar
Well spotted Target.

paint
glass
carbon
balsa
glass

Chris.
Jul 26, 2010, 07:40 PM
Detail Freak
target's Avatar
Just checking, and now you know that I read what you write.
Scary, huh?
Aug 02, 2010, 05:17 AM
Thermal Wrangler
DrFragnasty's Avatar

Raided Macdonalds


Slow progress but it's forward. Kind of...forgot to include the servo hole covers before the paint went on

CNC cut template for the fabrics helps enormously. Did a test cut of 3/4oz 'glass (sprayed with hairspray to retain weave integrity while handling) and the template fits just fine on the mold.

Marked out flap/aileron hingelines based on Drela Supra foils and the tip/centre panel cutline (80cm from root).

Raided McDonalds for a handful of straws for the aileron/flap sub-spar carbon sock to slide over. Dislike the food, like the straws.

Next up, cut the lower balsa skins to make way for the main spar and the hinge gap and the upper skins for the main spar. Bevel the edges of the skins at the hinge gap using Bruce's home-made sander.

Chris.
http://www.seat.org.au
Aug 04, 2010, 07:10 AM
Thermal Wrangler
DrFragnasty's Avatar

Progress


Progress is gathering pace;

Bruce is ready to make the new nose molds with a fashionable droop as per newer F3J ships. Again, mdf plugs but this time seasoned with Everdure and sanded/ polished and waxed ready to make molds from.

These plugs will be smothered under hydrocal; a method we have yet to try.

Stephen has sourced some key steel to act as a mandrel for the new joiner boxes; 7/16" x 1/2". The mold for which will be designed to allow us to do 2 joiners at once.

Chris.
Aug 25, 2010, 08:23 AM
Thermal Wrangler
DrFragnasty's Avatar

Slowly but surely


With next to no flying happening thanks to the sodden flying field you'd expect a lot of winter building here. The reality is work gets in the way of the fun stuff.

However progress is being made.

Stephen pushed out a boom; uni directional carbon with a Soller hybrid kevlar/carbon sock on top all applied under 2 heat shrink tubes .

The 2" tube wouldn't shrink sufficiently for the tail end so a separate smaller one had to be used.

Next up is pouring the nose mold and prepping the tail plugs.


Chris.


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