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My One off Cowl build

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Old 06-28-2011, 10:32 AM
  #1
chip_MG
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Default My One off Cowl build

Hey All,

Thought I'd post a couple of shots of my Bud Nosen Citabria cowl.

A little foam board epoxy glass and resins.

Oh what fun.

I did'nt really like the wood version as per the kit., so
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Old 06-28-2011, 05:45 PM
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Default RE: My One off Cowl build

Looking good!

A bit of sanding, maybe some microbaloons and you'll have a great cowling.

Although not as difficult, I made this cowling the same way. I used Polyester resin.
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Old 06-29-2011, 09:00 AM
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Default RE: My One off Cowl build

Good job.[sm=thumbs_up.gif][sm=thumbs_up.gif]
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Old 07-02-2011, 01:53 PM
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Default RE: My One off Cowl build

thx charles and rich,

yea, I guess I should have put off this post until I finish it..
I'll post an other pic when done.

I have made a dozen or so cowls, pants and other FG items using this method..
It work well, is fast and best of all, cheap.


happy landing ya'll

Chip
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Old 07-28-2011, 02:09 PM
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Default RE: My One off Cowl build

A shot of my progress..

It's a will soon be flying.. hope .. hope



Happy Landings Ya'll
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Old 07-28-2011, 03:14 PM
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Default RE: My One off Cowl build

WOW! Can't beat it, looks great, nice plants!
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Old 07-28-2011, 03:49 PM
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Default RE: My One off Cowl build

Thx Charles,

Did you say once you have used Poly resin for your projests?

I have not used polyester for some time, I like the West System epoxy, but it is a bit high priced , and slow to cure..

Happy landings Ya'll
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Old 07-28-2011, 06:53 PM
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Default RE: My One off Cowl build

Quote:
ORIGINAL: chip_MG

I like the West System epoxy, but it is a bit high priced , and slow to cure..

Happy landings Ya'll
You're using the 205 hardener? Try the 207 it goes a lot quicker. The have a Fairing compound that sands nicely too.
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Old 09-24-2011, 05:21 PM
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Default RE: My One off Cowl build

Dumb question coming "What is foam board?" Is there a more tech name for it?

Thanks

Prboz[:-]
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Old 09-27-2011, 11:07 AM
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Default RE: My One off Cowl build

the foam board I used for this is a 3/4 inch sheet 4' X 8' I got at home depot. I think is was $6.95 per sheet.
I glue it togeather with 3M77 spray also from home depot.
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Old 11-06-2011, 06:25 PM
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Default RE: My One off Cowl build

foam board is an insulation board that is used behind paneling or sheet rock or metal. you can buy it a just about at any hardware store. comes in a 4x8 foot sheet. great for makeing molds of any sorts.
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Old 11-11-2011, 07:44 AM
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Default RE: My One off Cowl build

Ok, so the lay-up is done over the mold, is there something coating the foam mold to keep the cowl from sticking to it? or do you just bust it out and toss away the rems?
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Old 11-11-2011, 08:27 AM
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Quote:
ORIGINAL: Mk23socom

is there something coating the foam mold to keep the cowl from sticking to it? or do you just bust it out and toss away the rems?
The way I do it is to cover the foam with packing tape, mold the piece, then pour some gas on the foam. The foam melts and the packing tape lets you take it out of the cowl neatly.
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Old 11-27-2011, 03:43 PM
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Default RE: My One off Cowl build


Quote:
ORIGINAL: soarrich


Quote:
ORIGINAL: Mk23socom

is there something coating the foam mold to keep the cowl from sticking to it? or do you just bust it out and toss away the rems?
The way I do it is to cover the foam with packing tape, mold the piece, then pour some gas on the foam. The foam melts and the packing tape lets you take it out of the cowl neatly.
I have used a couple of layers of regular kitchen cling-wrap to coat the mold. After cure it is easy just to pop out the mold pretty much intact for future use.
G42
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Old 02-13-2012, 05:59 PM
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Default RE: My One off Cowl build

Ok guys. You are obviously really experienced with this so please indulge some beginner questions. I have done a little bit of fiberglass work and have not been happy with my work because of wrinkles.

With this kind of complex plug with many compound shapes, do you do the layup with multiple narrow strips or is there a trick to getting a larger sheet to follow the curves?

How many layers do you use?
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Old 02-14-2012, 07:15 AM
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Default RE: My One off Cowl build

Can the foam be glued into a hole on a existing cowl and used as a plug? Then finished and sanded?
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Old 02-14-2012, 03:38 PM
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Default RE: My One off Cowl build

Hi Chick5,

I used 3m 77 you can get at the Home depot to glue the sheets together with. The foam board itself comes in 2' X 4' sheets or 4' X 8' sheets I think is was around $8 a sheet for the 4x8 size. It has other uses as well, in the hobby.

Blackdog, sorry for taking a long time to respond RCU has become so slow that I don't come here as much anymore..

But I'll outline the process I use to make a single item the cheapest that is.. If I need duplicates like wheel pants then I'll make a plug , and mold but doing that cost about 3 times the money and time.. Thats why Use the one off method for single items like cowls.

First cut the sheets to close size maybe 1/2 " larger all around to save sanding later. Use the plan profile to get the shape ya need, then glue the sheets together using 3m77..

Then sand to shape using course 30 - 50 grit sandpaper on a block. Use you plans to get the shape right. I make 3 cardboard templates for this one for each view.

When ya got the plug the shape you pleased with, then you just cover it in fiberglass glass using EPOXY resin,, Don't use poly or it'll eat the plug fast.. Polyester resin attacks most type of foam. Plus Epoxy resin in easier I think.. I cut the fiberglass 5 Oz type as large as I can get it to lay on the plug without pulling up.. It does'nt really matter because you'll be sand the fiberglass back to finish it anyway. I usaully will use 2 - 3 layers of 5 oz glass because I like a strong cowl.. If you sand a hole in the cowl It's no big thing cause you can always all more glass.. When your sanding use a dust mask and go outside, It can be messy.

After you happy with the thing, drill a large hole and put acetone or MEK to melt out the foam, also messy.

Thats it, after ya make a few things it'll get easy and you can learn to not be as messy..

Cheers, and happy landings to ya

Chip
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Old 02-14-2012, 08:58 PM
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Quote:
ORIGINAL: chicks5

Can the foam be glued into a hole on a existing cowl and used as a plug? Then finished and sanded?
I've plugged a hole in the cowl, but the other way around.
First I used a piece of mylar on the out side of the cowl, then put glass on the inside of the hole and cowl. The mylar leaves a smooth surface on the "plugged part" with very little finishing needed.
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Old 02-14-2012, 11:42 PM
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Default RE: My One off Cowl build

Yes, You can use an exiting cowl as a mold. I have done that from kits when there where kits to build that is , only a few left.. There is not much varity anymore for kits so I like building from plans. Its slower of course but I love to build stuff.. Most of the kits used to have abs plastic cowls, they'er not too tuff so one noseover on the pavment and a cracked cowl you'd have. Fiberglass ones can be alot stonger..
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