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All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

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All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

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Old 02-25-2012, 05:39 PM
  #51  
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Default RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

Quick mock up to fire me up to finish.

2nd wing tank .25oz lighter due to lighter seam tape and large CNC cut lightening holes in balsa discs. Totally pinhole free.

Excuse the lack of cleanliness.
It's organized though.

steve
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Old 02-25-2012, 05:46 PM
  #52  
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Default RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

By the way, i made goggle/joggle gaskets for this tank. However my spinning method works very well and could be easier. (less cabosil during layup.)

Many options though.

steve
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Old 02-25-2012, 09:06 PM
  #53  
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Default RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

Hi Steve,
Great stuff...a labor of love. I have the BIG Jacknife sport jet. I prep my molds with freekote, shoot some K-36 primer and do the lay-up. I seam the tanks using balsa square stock along the seam, and then Aeropoxy to close it up. I pop the part and it's already in grey primer. Finish is as good as the mold. Keep up the great work!! Visit the Knife at www.wereoutofthisworld.com

Take care,
Jack Holland
Team Jacknife
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Old 02-25-2012, 10:20 PM
  #54  
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Default RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

Hi Jack
Thanks.

Nice large jet. A talent.

Yes a labor of love. Most days anyway.

Years ago we used to offer full composite warbirds (1990). In the days of production, we used to prime in the mold. For me personally, I like to see through my models.


steve
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Old 02-26-2012, 10:02 AM
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Default RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

Jack

The Jacknife is a fine looking ship. I love the military paint scheme, VF-103 was my last command before I retired from the Navy, seems to be the most commonly modeled squadron.

Peace, Wolf
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Old 03-03-2012, 12:34 AM
  #56  
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Default RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

Very nice, glad to see ur still working on it. How did you secured wing tips tanks of the wing, did u make any removable type of mounting system....

Any ideas about the landing gear....
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Old 03-03-2012, 08:19 AM
  #57  
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Default RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

Landing gear will be electric. Either a rotating set for mains, or regular. With gear doors, in any case may not matter too much.

Wing tanks will be attached with a ply section sticking out of the wing at first anchored to two slotted balsa discs in the tanks. See pics. Later with the composite permanent wing

design, like the Avons. The wing tank slips over the wing tip (I'll have to add to the tip).

Steve
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Old 03-25-2012, 08:55 AM
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Default RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

A quick update on a new method I'm trying.

These are the fuse intake ducts. i am using automotive modeling clay. It is very hard, fast and can be molded, reshaped, reused, corrected, glassed, softened to dough like feel to apply. The base carrier is still foam with around a 1/2" of sheets of clay. Not solid clay.

It is amazing stuff. Can be made to have a glossy surface as well.

Around 45 min of time invested.

steve
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Old 03-25-2012, 08:56 AM
  #59  
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Default RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

Forgot the pics.


Steve
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Old 03-26-2012, 06:15 PM
  #60  
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Default RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

Hey Steve

Where are you sourcing the clay? Does it require heating to soften it.

Wolf
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Old 03-26-2012, 06:53 PM
  #61  
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Default RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

ORIGINAL: BD5wingnut

Hey Steve

Where are you sourcing the clay? Does it require heating to soften it.

Wolf
Hi

The clay is from Fiberglast. It is Y2K clay. Yes, it has to be heated to be applied. For best results it should be slow heated to heat all the way through. I roll mine into 1/2" thick flat sheets and put it in my truck on sunny days and it is very easy to apply. It comes in a 2" solid rod around 10" long. Very hard when cold. Cannot even bend 2" rod.

But once you get used to using it, it's really great and fast. Plus no DUST!!!!!!!!!!!!!!!!!!!!





Steve
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Old 03-27-2012, 09:52 AM
  #62  
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Default RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

Yeah that is the same stuff, cool.
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Old 03-31-2012, 06:07 PM
  #63  
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Default RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

Trying the clay out on the forward section for the canopy plug. I think it's gonna work.

By the way, I took a quick "bondo" mold off one of the intakes (formers showing) to get a glass intake laid up and and mate up to the fuse intake.

The clay after wax and pva, around .5mm stuck to the bondo. Was easily removed with a small scrub brush and warm water.

Steve
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Old 04-03-2012, 07:28 PM
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Default RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

Pulled a quick bondo mold off one of the clay intake plugs. Then laid up a quick dirty polyester glass intake to fit to fuse, then to be finished as a plug and the final epoxy glass mold will be made from that.

Also, I made the intake spike plug out of clay on my lathe. It did manage to stay in the chuck while I trimmed it with a spring steel metal "blade". Finished nice enough to pull a mold right off the lathe.

Steve
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Old 04-03-2012, 07:33 PM
  #65  
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Default RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

Machining clay?? YOU DA MAN!!!
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Old 04-04-2012, 07:46 AM
  #66  
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Default RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

Surprised me as well!

Steve
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Old 04-04-2012, 08:51 AM
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Default RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

Seems perfectly reasonable to me... I have turned Jade and Onyx with excellent results. Good thing you used a throw away cutting tool since the clay could have damaged a good tool.
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Old 04-04-2012, 10:05 AM
  #68  
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Default RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

BD5

The cutting tool is a drywall knife blade I cut into small strips and used those as needed. Held by hand as in wood turning with "rest". I guess.

At this point, I have parted the clay plug spike on it's center line to produce 2 mold 1/2 spikes. They are exactly the same, parted with styren plastic.

Quick dirty temporary bondo mold to get parts out of and fabricate rest of intake duct,liner, ect.

I'll use this same method for my composite MiG 21MF spike later.

Steve

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Old 04-05-2012, 07:32 AM
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Default RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

How the bondo mold turned out.

The clay survived very well. loss of about .25mm of surface skin mostly. This was due to the clay being used without adding any clay. No air pockets I would guess.

The bondo does have a few layers of scrap glass glass to reinforce the bondo. It's not only bondo.

Next the glass parts.

Steve
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Old 04-06-2012, 06:46 PM
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Default RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

Hi All

Got some glass intake spikes out of the bondo molds today. Now to set the intake boundary layer at fuse, and fabricate the fuse side of the intake to have the forward sweep at the intake "LE".

The clay makes things very fast and easy. Total time in fabricating plug, to bondo mold, to part is around 1hr 15min.

Steve
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Old 04-12-2012, 07:11 PM
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Default RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

The forward sweep on the boundary layer LE and the mock up of the boundary layer gap.

Next to fit all to fuse.



Steve
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Old 04-12-2012, 07:13 PM
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Default RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

This was what I'm shooting for in the above pic by the way.

Steve
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Old 04-12-2012, 07:13 PM
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Default RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

Really starting to look good Steve.
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Old 04-13-2012, 05:53 AM
  #74  
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Default RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

Thanks Slow
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Old 04-13-2012, 07:31 AM
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Default RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

A quick pic of the only use I have for monocote today ( can also use mylar, or glass table,ect...waxed of course ).

Making sheets of composite. In this case, I need a flexible smooth surface sheet for the scale intake at the boundary layer.

The material is "e" glass crow foot weave around 3.5oz x 2 . It yields a perfect pin hole free finish. I used epoxy since I ran out of the polyester resin catalyst.

Peels clean from monocote. Surface will be as shinny as monocote

Cheap and very easy.

Steve
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