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Dec 10, 2019, 01:11 AM
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Tomorrow will tell


One half of the wing mold cast .
I can separate it late tomorrow and start the other side
My rec room was spelled wrong
Its really a WRECKED ROOM .
BOY WHAT AN AIRPLANE CATASTROPHY
I buy my fiberglass mat from a fiberglass part manufacturer .
Their scraps are huge and inexpensive .
I got lucky last time and got a guarbage bag full of heavy cloth for40 dollars . I wont run out for a long time using it as finishing cloth for molds .
Last edited by leo turt; Dec 12, 2019 at 04:10 PM. Reason: Morepictures
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Dec 13, 2019, 04:35 PM
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Molds are done


I have a couple molds ready to make composite wings
But wouldnt you know it im out of epoxy
Dec 25, 2019, 01:03 PM
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Mold wasxed and pva applied


I managed to get the spar built and a pattern for cutting the balsa and cloth made
Straightening Glueing and cutting balsa sheets takes a bit of time and really uses up the balsa .
The epoxy came from florida in a 10 days .
Dec 29, 2019, 09:36 PM
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Well this is a lot more work than it seems .
I have the top half done .
Now to build a spar etc .
Dec 30, 2019, 11:55 AM
DHG
DHG
Kinetic Sculptor
Quote:
Originally Posted by leo turt
Well this is a lot more work than it seems.
Yes.

But then, isn't everything?

Looks great so far! Thanks for the updates!

Cheers,
Duane
Dec 30, 2019, 01:43 PM
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The spar is in .


As you can see the glue pulled the print off of the plastic .
The spar is made like the glider guys do it .
There are a few adjustments needed i had to sand the trailing edge as i got the balsa too thick back there now ill have to wax and pva the mold edge again so i dont glue everything together when I join the wing .
I taped it when i was sanding but you can't be too careful.
Dec 30, 2019, 08:24 PM
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Weight


Controlling the amount of epoxy used is tough .
When I built the spar the vacuum bagging actually pulled the glue thru 1/6 " balsa . It aso pulled it out the perimiter as expected but the glue in the wood will be added weight .
I guess less next time but how much is enough or too much ??
Dec 31, 2019, 01:11 AM
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A hinge next


I tried cutting Keclar with knives and every pair of scissors in the drawer .
Almost gave up on it until i found these .
The left side is the old cuts the right i pulled a thread and cut on the dotted line eeeeaaasssy .

I may pour a second plug if repairs don't work out
Pour would be fast with Duram's hard rock putty available only
In the US .
Last edited by leo turt; Dec 31, 2019 at 01:56 AM. Reason: More words
Dec 31, 2019, 11:20 AM
DHG
DHG
Kinetic Sculptor
Quote:
Originally Posted by leo turt
When I built the spar the vacuum bagging actually pulled the glue thru 1/6 " balsa ... the glue in the wood will be added weight . I guess less next time but how much is enough or too much ??
Len,

Whenever I'm fixin (colloquial American term) to laminate balsa, I prime it with a coat of nitrate dope, then lightly sand. The nitrate dope is very light, dries fast, and fills the grain so the epoxy won't penetrate as far.

Could you elaborate a little more on what sort of "carbon" you're putting between the layers? Is it that veil/tissue stuff, or a woven CF cloth, and what weight are you using? Also curious about that "Duram's rock hard putty" ... sounds good but I've never come across it. Smooth-On makes a wonderful, feather-light epoxy putty but it seems a waste (and probably extra expense) to use it for molds.

Thx, and happy new year!
Duane
Dec 31, 2019, 12:33 PM
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Durams Rock Hard putty


Ive used durams for making plugs for canopies add water stir pour it into a clean canopy no wax or pva required .
It comes out very easy with a shot of air .
Then you cook it at low heat for a while to harden and dry it .
Being the balsa plug is mangled Im thinking i will make a plug with my new stab out of durams so I can have two identical haves to put together in the molds.
Its light carbon veil long random strands .
I was thinking i might try to woodpecker the balsa a bit so the glue passes thru i'm always afraid to seal the wood and cause delamination but im just likely worrying too much . Getting any light carbon up here is almost impossible .
And Composite Envisions wont ship to canada .
Last edited by leo turt; Dec 31, 2019 at 12:39 PM. Reason: More words
Dec 31, 2019, 12:48 PM
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Its very light carbon veil long random strands .
Its tough getting light carbon up here .
Composite Envisions wont ship to canada .
And if small amounts are shipped on a roll the freight is a killer .
I was thinking i might try wood peckering the balsa so the glue passes thru .
Sealing it is a good idea and would help reduce weight .
Dec 31, 2019, 02:29 PM
DHG
DHG
Kinetic Sculptor
Niiice! So 100% nylon works like Peel-Ply, but cheaper. Me likey!

Also, I think you've hit on something with that Woodpeckering idea. Seal the wood with nitrate dope, then make evenly spaced, uniform holes with the Woodpecker. That creates a matrix or honeycomb sort of structure when the resin fills those holes.

Between the two of us, I'd say we add up to at least one entire wit.

Cheers,
Duane
Dec 31, 2019, 03:22 PM
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Not as bad as it looked


I glued some pieces back in
Then bondo 80 grit sanding then scratch putty now 400 grit and primer then back to paint..
I blame that on my teacher Duane she said don't get smart with me young man sooooo...
Last edited by leo turt; Dec 31, 2019 at 07:49 PM. Reason: Add pic
Jan 01, 2020, 02:04 PM
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Success


It was a lot of work but now that its out of the mold its straight and smooth no filling required where the glass is doubled .
Once i get lay up bagging an part sizes down it should go a lot easier .
Any blemishes i find in the surface will need to corrected in the mold . I see one dent in one wingtip i may have caused it with the
Credit card or it might be a high spot in the mold
The hinges are rough to do it should be easier each time. As i will have a better idea of the sizes .
Pardon my thumb sometimes it misses when i type .
Last edited by leo turt; Jan 01, 2020 at 02:14 PM. Reason: Morepictures


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