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  1. #1
    SCALECRAFT's Avatar
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    All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

    Hi All

    I have found 100% scale drawings of a real F-104 Starfighter on the net. The drawing has fuse cross sections. The hard part is getting used to what line to use from a very large pixelated "line". I had my kid enlarge them to what I wanted and away we go. 67" fuse without spike, 31.5" wing span.

    I am mostly posting this project on RCG electric Jets forms but thought I would show a simple and fast method of fabricating pretty much any airframe you may want if you find drawings.

    From paper to plug, to composite airframe, to flight.

    Our group of 3 guys have made around 15-18 full composite scale warbirds since 1990. It may not be the best way, but it yields us all any model we want. And as many. Inn a very short amount of time.

    The profile on the tracing paper is for the parting board/splitter board later.

    Few hours of play time a day and within a week, I almost have my fuse shape

    We do it for fun.

    Steve



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  2. #2
    Slow Low's Avatar
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    RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

    Oh Boy! Count me in: I'm subbed.
    From possibility to actuality.
    http://www.zazzle.ca/two_bulldog_brand*

  3. #3
    SCALECRAFT's Avatar
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    RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

    A bit more progress. Foam shape will be patched, glassed, fine patched primed in two shades of primer to warn that glass is close when scribing panel lines and other details.

    Also will have a variable thrust nozzle. Inside fuse as in full scale one.

    Steve
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  4. #4
    soarrich's Avatar
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    RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

    Looking good![sm=thumbup.gif][sm=thumbup.gif]
    Rich Border AMA 77727
    Sig Kadet Brotherhood #2

  5. #5
    SCALECRAFT's Avatar
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    RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

    The latest work. The ducting done another way. A better way, I Think.

    Steve
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  6. #6
    SCALECRAFT's Avatar
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    RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

    After much scrap cuts and ridicule from my teenagers, I finally came up with the patterns to cut the scale intake. Tapered slightly down and angled back as in scale.

    Next week, the Nose to cockpit transition done more accurately.

    The shock cone is just for looks and not in the proper location or shape/size

    Steve
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  7. #7
    SCALECRAFT's Avatar
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    RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

    Glued foam sections I liked to profile, then patched with light weight wall patch tinted with blue food coloring to make it easy to see.

    Next is canopy formers and nose section.

    Steve
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  8. #8
    SCALECRAFT's Avatar
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    RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

    Decided to do nose section before canopy.

    Had a chance to go to Chino Planes of fame museum. They have a F-104G. Looking at this pic, I tapered the nose a bit more like the scale pic after I posted it.

    Steve
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  9. #9
    soarrich's Avatar
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    RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

    Looks good. Isn't it surprising how small it is in real live compared to today's planes?
    Rich Border AMA 77727
    Sig Kadet Brotherhood #2

  10. #10
    SCALECRAFT's Avatar
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    RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

    True. It was surrounded by other jets of the era, and it was quit a bit smaller even for it's own time. Today, it could be nose art for some of the world's modern aircraft.

    steve

  11. #11
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    RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

    Update on progress.

    Canopy plug shaped, V stab airfoiled and shaped, tail cone top fairing (clear plastic) made.

    Steve
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  12. #12
    Slow Low's Avatar
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    RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

    What are you using for materials there Steve? Looks sandable.
    From possibility to actuality.
    http://www.zazzle.ca/two_bulldog_brand*

  13. #13
    SCALECRAFT's Avatar
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    RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

    Internet scale 3views scaled up to size wanted (kid on computer). Must show fuse cross sections, top, front, bottom, and side. A couple of plastic models you will commit to for 3 dimensions. Pics of a full scale at near by museum.

    White foam wall insulation from Home depot for fuse, hot wired. 1/8" luan "door skin" for patterns/formers. ...........Would not use foam again, too light density, damages easy.

    Florist green foam for canopy carved/sanded, not hot wired due to toxic fumes, local craft shop. Light weight wall patch from Home depot. Various food coloring added to see new from old patch. Easier for my eyes to see.

    Once shaped pretty smooth, then glassed and final shaped with bondo. The final shaping will be way faster due to fast cure time of bondo oppose to waiting for wall patch to dry.

    Steve

  14. #14
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    RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication


    ORIGINAL: SCALECRAFT

    White foam wall insulation from Home depot for fuse, hot wired. 1/8'' luan ''door skin'' for patterns/formers. ...........Would not use foam again, too light density, damages easy.
    Get Dow Hi Load 40 or 60, you'll think you have super-light balsa.
    Rich Border AMA 77727
    Sig Kadet Brotherhood #2

  15. #15
    SCALECRAFT's Avatar
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    RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

    Decided to glass and prime the forward fuse section. Foam kept taking damage.
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  16. #16
    Slow Low's Avatar
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    RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

    Two steps forward, one step back. Glass cloth and resin'll make short work o' that...
    From possibility to actuality.
    http://www.zazzle.ca/two_bulldog_brand*

  17. #17
    SCALECRAFT's Avatar
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    RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

    The idea was to shape and smooth the foam as close as possible then glass. Got tired of filling the same spot from denting it.

    Steve

  18. #18
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    RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

    Wing mock up. Calculations from the three views show that I need to add 1" to the wings leading edge to be exact scale.

    Steve
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  19. #19
    SCALECRAFT's Avatar
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    RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

    Canopy compound section done and sprayed chrome silver to show if true. Next canopy flat sections out of styrene plastic, then framing with alum duct tape.

    Also the front section of the wing tank turned from florist foam.

    Steve
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  20. #20
    Slow Low's Avatar
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    RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

    haha you're making me feel very guilty for the break I'm on at the moment....lol

    Looks fantastic.
    From possibility to actuality.
    http://www.zazzle.ca/two_bulldog_brand*

  21. #21
    SCALECRAFT's Avatar
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    RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

    Thanks Slow

    I only work on the plug an hour or so a day. Some days I stay away from it.

    Especially when things don't turn out as I thought they would when shaping parts.

    Keeps me from tossing it and starting over!

    Steve

  22. #22
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    RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

    Decided to make the wing tank.

    Need just one for the mold.Same for each side.

    Steve
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  23. #23

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

    Looks like ur building F-104A's model there, looking great. How r u planning to make it's wing as i see construction grade plywood templates made n attached for wing n tip tank?

    Is this one off model or ur planning to make few kits also. I'm interested in getting a F-104A's kit from u in case ur going kit ur model....
    I do believe in KISS (Keep it simple silly), but doesn\'\'t mean my models fall in this category!
    CUB BROTHERHOOD# 173

  24. #24
    SCALECRAFT's Avatar
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    RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

    Hi Props

    Slowed a bit , but still moving forward.

    This entire model will be a composite model.

    It had been on hold till a few days ago. The wing airfoils are being decided right now. I should have the wing plugs by 1/15/12 cut out of foam and balsa covered at first. Then if a good forgiving fast wing, it will be molded.

    I will post pics later in the week.

    Steve

  25. #25
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    RE: All composite 1/10 F-104 scale 90mm edf plug/mold fabrication

    A pic of the latest work. The wing are going to be glass similar to all the WWII warbirds we have. Only these will be easier since no gear involved in frame work.

    The wings shown are foam cores and balsa capped with balsa ribs at the tip. If these wings prove to be fast, and forgiving at landings on the composite fuse, then they will be the ones to become composite.

    I do however have a bit of a set back. The intake does not taper down into the wings TE. It stays almost constant. The cross sections I used where incorrect at that location. The red line shows the correct shape of the intake taper.

    Oh well. have to fix that. But I only have to do it once!

    Steve
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