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Fuselage Nose Repair Ideas

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Old 09-03-2012, 11:22 AM
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sidgates
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Default Fuselage Nose Repair Ideas

I need to repair the nose of this fiber glass fuselage. Most of the top and one side are still intact. The other pictures shows a lot missing on the bottom and the other side.

If I just glue the exiting nose to the fuslage there is very little room to work on the inside of the nose. I am thinkin of trying to make a fiber glass sleeve that fits the inside of the nose piece and the front of the fuselage.

Any other ideas welcomed.
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Old 09-06-2012, 07:42 AM
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Default RE: Fuselage Nose Repair Ideas

That is a good simple way. I would make a sleeve that I have glued to the fuse first and extends out a bit, then glue nose to it. Securing the nose "joint" with tape wrapped around the fuse/nosewhile it cures.

If your fuse is polyester (smells like a boat factory) use polyester, if epoxy, either resin will work.

This is why I like removable nose sections.

Steve
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Old 09-06-2012, 09:18 AM
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Default RE: Fuselage Nose Repair Ideas


Quote:
If your fuse is polyester (smells like a boat factory) use polyester, if epoxy, either resin will work.
I would use epoxy to make the repair regardless of the resin used to make the fuse. Polyester makes very poor mechanical bonds. Epoxy will stick to cured polyester better than polyester will stick to cured polyester. Polyester sticks to epoxy very poorly.

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Old 09-06-2012, 09:53 AM
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Default RE: Fuselage Nose Repair Ideas

Steve - Adam
Thanks for the replies. Epoxy only for me. I haven't had time to get started on the repair so still studying the best way. The existing nose has lots of cracks and some missing pieces so I am leaning toward a complete new nose. There is an existing bulkhead in the fuse about 1" back from the ragged fuse end.

My current thought on plan to repair. I will tack glue the existing nose piece on the fuse nose and then make a verticle and horizontal template of the nose shape. Next shape a new nose plug out of blue foam. I will cut off the fuse nose about 1/2" in front of the bulkhead. Then lay up the new nose on the blue foam and after cured, remove the blue foam from the inside. Next glue a splice inside the fuselage nose approx 1/2" and 1/2" protruding to pick up the new nose. I plan to start tomorrow.
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Old 09-06-2012, 05:13 PM
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Default RE: Fuselage Nose Repair Ideas

If your going to attach the nose to the fuse, would it be feasible to take make a mold off the nose section once on the fuse?

Just "part" or put a 'splitter" board at a location that would be best for your application.

That's what we do with sections we want parts of.

Steve
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Old 09-06-2012, 07:13 PM
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Default RE: Fuselage Nose Repair Ideas

I could make a mold but didn't think it is worth it for just one part. It would be a simple mold and I gave that idea some consideration.
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Old 09-10-2012, 08:14 AM
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Default RE: Fuselage Nose Repair Ideas

I started a plug for a new nose and used pink foam I had instead of blue.
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Old 09-12-2012, 04:07 AM
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Default RE: Fuselage Nose Repair Ideas

New nose foam plug ready for final shaping and sanding.
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Old 10-21-2012, 08:27 AM
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Default RE: Fuselage Nose Repair Ideas

Nose repair finished with one coat of primer. Getting a smooth finish on the outside took nearly as long as making a female mold and then making a new part.
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