kleinatze

Hi KM!

We started with 60 rips we milled out of MDF. These rips we bead on an aluminium tube. We decided to build the plug out of these rips because our cnc milling machine has only an traversing path of 600mm.

After sanding,painting and so on one gets an quite accurate plug. The wing tips are hand-shaped ;-)

For the mould - building we used glas fabrics and poraver (leightweight glas bubbles, diameter 2mm) which are mixed with resin.

A short description:
After waxing:
- application of the grey mould resin
- after 3h: fill all egdes with resin + cotton
- 3 layers 80g/m^2 + 3 layers 280g/m2 gas fabric
- make a mixture of resin and poraver (1 litre epoxy for 10 litre poraver )
- fill the mold with the mixture
- after the hardening process is finished: 3 final layers 280g/m^2 on the poraver

The mould are very lightweight and stiff.

I hope this descriptions helps a little bit..

Andreas