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Old Nov 27, 2011, 09:53 PM
samc99us is offline
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Aurora Builder
Build Log

Aurora DLG-Molded in the U.S.A


Since my mold maker dropped the bomb over in the other forum and I've dropped enough hints elsewhere, I guess its time to start a new thread for a new era.

Introducing the Aurora DLG-molded in the U.S.A, on the footsteps of the Washington Capitol!

Wing: Custom designed Zone V2. I optimized for float and forgiveness a bit more over absolute launch height and range performance. I have a prototype 10 panel bagged wing cut on my CNC hotwire and bagged with absolute precision. Unfortunately it didn't get any air time before the molds were cut, but I have full faith in the design and will be putting this wing in the air shortly.

Fuselage: The prototype bagged wing will be sitting on Adam's one-piece fuselage. I will likely interchange the first flying molded wing with the bagged wing on this fuselage. A one piece mold is in progress by the rest of the build team but these parts will remain undisclosed. Design work on an in-house fuselage is on going and will lead to a truly special fuselage design.

Tail Design: I'm following Gerald's rudderless design work very closely. The wing was not designed to be rudderless, as I am a believer in the rudder, but rudderless will get tested thoroughly before a decision is made on this front. Horizontal tail will likely use the Freak Horizontal V2 but the computer modelling is a little stalled at this point so the details have not been drawn up. Tails will be fully molded once a proper design is complete.

I'm curious what folks would like to see in this thread-design work, build work, finished product? I doubt I will have the energy to photograph everything, especially during time critical layups but I can do my best. For now enjoy the photos!
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Old Nov 27, 2011, 10:00 PM
samc99us is offline
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Pictures of the bagged prototype wing, leading edge is an absolute work of art.
Old Nov 27, 2011, 10:02 PM
The_Builder is offline
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who cut the molds?

paul
Old Nov 27, 2011, 10:06 PM
jcats is offline
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Launch high. Fly low.
Cool! another molded plane in the US!
Let's see everything in the thread- design, build, etc... even how a servo hatch feature can be molded in... seriously.

Good luck, Sam!

Jun
Old Nov 27, 2011, 10:14 PM
samc99us is offline
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Molded in wing servo hatches, forgot about those. Won't be in the first wing pulled from the mold but I'll stick them in the second (first flyable wing).
Old Nov 27, 2011, 10:28 PM
NCDLG is offline
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Nice 10p wing!

Looking forward to seeing it in action...soon!

Keep up the great work!

Eric
Old Nov 27, 2011, 11:05 PM
samc99us is offline
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Lots of questions coming in over PM's. I'll answer a few:

1) Molds were cut by a gentleman in Maine. If you would like a set, I am sure he can cut another. Contact me via PM, we can work something out if you wish to use this design.

2) Mold finish is as shown in the photos, I have not received them so I cannot comment directly but its fairly clear it is already pretty dang good. An hour or 2 of sanding should get them mirror smooth.

3) Mold material is Corian backed with MDF.
Old Nov 27, 2011, 11:32 PM
jcats is offline
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Launch high. Fly low.
You know what I'd like to see molded in? Control rod tubes or sleeves for the rudder and elevator.

Jun
Old Nov 27, 2011, 11:40 PM
tom43004 is offline
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Father of Fr3aK, DLG Pilot
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I've seen some of his other mold work. You'll be highly pleased.

Great stuff Sam. If you want a set of my videos, I have my layup processes documented heavily on 1080p blu-rays. Maybe by seeing what I've done you can avoid making some of the mistakes I've made along the way I shared them with a few guys on the East coast already.

Looks like the revolution has started

Molding hatches is easy, provided your wing is thick enough for them.

After a while you'll get used to taking pictures while doing layups and chasing the clock in a warm shop. Soon it will be routine.

Remind me to share some "Made in the USA" stickers with you next time I see you. Every wing that comes out of these deserves one.
Old Nov 27, 2011, 11:56 PM
rexnuktia is offline
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Quote:
Originally Posted by samc99us View Post
I'm curious what folks would like to see in this thread-design work, build work, finished product?

Everything please ! So exciting to see another made in the USA product !
Old Nov 28, 2011, 12:02 AM
samc99us is offline
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Thanks Tom, I spent a few hours looking at the videos you have up online but the full collection would be nice, I've learned a ton already with the footage you have posted (forcing me to spend a hunk of change with CST lol).

Jun, that is in the cards for the fuselage. Keep the design feedback coming, without input from folks putting ships together better designs wouldn't be possible!
Old Nov 28, 2011, 12:37 AM
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Subscribed

Brandon
Old Nov 28, 2011, 02:18 AM
tai626 is offline
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One more "Molded in USA"!
I am saving up for your dlgs, keep up!

Tai
Old Nov 28, 2011, 03:41 AM
wyowindworks is offline
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Just fly it!
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Quote:
Originally Posted by samc99us View Post
3) Mold material is Corian backed with MDF.
Looks good, Sam.

Watch out for the expansion differential between the MDF and Corian.

The CTE of Corian is 3.02 x 10-5 in/in/C*
MDF is 1.2 x 10-5 in/in/C*

The really kicker is the expansion due to moisture change. MDF with expand .4mm per meter per 1% moisture content change. 30% Relative Humidity to 60% could change the moisture content by 3%. If you are shooting PVA and cleaning with water you need to be really careful. If you tried to seal the MDF with resin at this point the back of the MDF will really expand and bow the mold. If the MDF was sealed before it was adhered to the Corian then you may be golden.

Neither of these may be an issue, but I thought of it right away when I saw the two materials together in that configuration.
Last edited by wyowindworks; Nov 28, 2011 at 04:05 AM.
Old Nov 28, 2011, 03:53 AM
ThomasLee is online now
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Nice! Another project to be envious of!
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