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    84 inch P-51 Mustang Plug, Mold and Fuse fabrication


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    84" P-51 Plug then Mold build, fuse to come. - 1/10/2013 9:51 AM

    trent smith






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    From: hampton park, AUSTRALIA
    Status: offline Hello all, I have had a growing interest in producing fiberglass parts of different sizes and model types for a while now and after producing a fuse of a 82" Sea Fury from a set of purchased molds I decided I wanted to make my own molds of my fav warbird,the P-51 mustang. I obtained a damaged beyond fixing giant scale Topflite P-51 arf and used this as my blank canvas, and stripped back to balsa and started a few modifications to make more scale in my eyes. I got a cowl with the correct spinner diameter from Leo Spychalla and blended in the front of the fuse to look nice. I filled in the dorsal fin in to make it more triangular in shape and raised the horizontal stabilizer up approx 5/8" up to scale location. Also I made the cocpit size better and made a hood of sorts blended in to the fuse. I then glassed and primer filled, sanded and did panel lines with the chart pack tape using 3-view drawings as best as I could. I did raised panels around wing and tail plane fillets as well. Another thing I did was make a exhaust location indicator which can be cut out if I wanted to use Tony Howards 1/5 exhaust kit. I have not yet worked on lower chin cowl and radiator scoop but they are next on the list. I made a parting board from white malamite standing on a box to support the glassing project. I waxed many coats of 100% carnuaba and then a few mist coats of PVA and I am ready to go. I then sprayed Tooling Gelcoat followed by many hand layed up layers of chopped matt to get a strong mold with plenty of support. Fipped it over and repeated the process . I will post a few posts of photos to give a impression of how things went. I popped the Plug out of the mold and was very happy with the result and basically no sticking between plug and mold. I will try to pull a fuse out of this mold when I get a chance in the future. Cheers Guys Trent.

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    RE: 84" P-51 Plug then Mold build, fuse to come. - 1/10/2013 9:57 AM

    trent smith






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    RE: 84" P-51 Plug then Mold build, fuse to come. - 1/10/2013 9:59 AM

    trent smith






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    RE: 84" P-51 Plug then Mold build, fuse to come. - 1/10/2013 10:01 AM

    trent smith






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    Status: offline and a few more.....

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    RE: 84 - 1/10/2013 11:37 AM

    BOLTMAN






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    Status: offline Looks good Trent.

    It would be good to see more of this sort of thing available here in Oz

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    RE: 84 - 1/10/2013 11:44 AM

    G T






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    From: darwin, AUSTRALIA
    Status: offline Hi Trent.

    Excellent work there,, how do you find the time as the images have the kids gear in them so I would think you have your hands full there .. Keep up the good work and the progress posted please,, Now get back to the "Tempest"

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    RE: 84 - 1/10/2013 11:52 AM

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    quote:

    ORIGINAL: G T
    Now get back to the 'Tempest'


    No, best to get focused on the P-51 & send the Tempest to me to take care of.

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    RE: 84 - 1/10/2013 8:06 PM

    trent smith






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    Status: offline Hi Guys, I hope to get this project to a point where i can offer a basic kit with fuse, cowl ,radiator scoop,canopy ,wing and tail foam cores and some basic drawings similar to the Model Design kits of old. There is a market for the air races here in oz for the category which have the warbirds. Re the kids G.T. they take up a lot of time but thats a great thing as they love being outside with Dad and I know that they will get to an age where they may not want to spend as much time with me so I am taking full advantage of these years even if modelling and hobbies have to wait.

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    RE: 84 - 1/11/2013 2:39 AM

    G T






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    From: darwin, AUSTRALIA
    Status: offline Hey Boltman
    I wanted first pickings on the Tempest .. Haha

    Yes read you on the kids front Trent,, some times I think I lost the plot with mine as I was to busy with all of the other stuff & business.
    Just had my flying mate here from Alice with his young family so I got the feeling I might make a better grand pa than I was a dad..
    Spend as much time as you can with the kids while they are young...
    The kit plan sounds good,, the direction with the air races should give you a good market.

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    RE: 84 - 1/11/2013 2:56 AM

    rc34074



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    Status: offline Did you get rid of the edge of the wing fairing along the side of the fuselage? This would be a nice fix for the Top Flite design. Perhaps you could leave a line there but eliminate the step at the end of the fairing.

    Ed

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    RE: 84 - 1/11/2013 3:20 AM

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    From: Ampur Mae TaengChiang Mai, THAILAND
    Status: offline Trent.... Very good thread here and thank you. Did you take any photos of what the board and mold look like after you got done adding the chopped matt and were waiting for it to cure? Curious as to how that stage looks. I've always wanted to give mold making a shot.

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    RE: 84 - 1/11/2013 3:52 AM

    trent smith






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    quote:

    ORIGINAL: rc34074

    Did you get rid of the edge of the wing fairing along the side of the fuselage? This would be a nice fix for the Top Flite design. Perhaps you could leave a line there but eliminate the step at the end of the fairing.

    Ed

    I am not 100% what you mean but I think that the mods I did here were to blend in the vertical top edge of the wing fairing and stop with the raised panel line. I have a Comp ARF p-51 as a reference and its not bad compared to that. I may take a pic of the plug to show what I mean.

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    RE: 84 - 1/11/2013 4:05 AM

    trent smith






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    quote:

    ORIGINAL: thailazer

    Trent.... Very good thread here and thank you. Did you take any photos of what the board and mold look like after you got done adding the chopped matt and were waiting for it to cure? Curious as to how that stage looks. I've always wanted to give mold making a shot.

    For some reason I took no photos of that stage... dont know why??? After spraying the Tooling Gelcoat and letting almost cure antil just slightly tacky I ripped up 225gram matt and layed around all corners and 90 degree areas and then covered the entire plug in a thin layer of 225 gram glass known as the 'Lock Layer' which is rolled to remove any air bubbles which are very bad and then allowed to cool. Then I lightly sanded the entire thing and give another layer of 225gram glass, allow to cool and sand again. Then I did another layer of heavier matt which is about 45o grams, sanded and reapeated once more. I built up further small layers in specific areas which i felt req additional strength. Then i carefully lifted off from the 16mm parting board and cut and cleaned up the edges to about 1 1/2 " all around. I then supported the inverted plug and did it all again with wax, pva,tooling gelcoat and glass. I had read and youtubed alot about how difficult removing the mold from plug was but it came out in about 10 min with 3 wedges and a bit of pulling and tapping with a mallet. Youtube has heaps of great tutorials on fiberglassing which I have learned a lot from and also read in other posts from fellow modellers on this and other R.C. sites. Stay Tuned Trent.

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    RE: 84 - 1/20/2013 3:40 AM

    trent smith






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    Status: offline Hello again guys, I have moved on to the next parts which I will be making molds for on this P-51 mustang, the air scoop, lower chin cowl and I am going to make a composite rudder with as much detail as I feel up to doing. I started this project with learning how to make molds and various composite parts so I will continue to make parts for this plane and who knows where it may end? I continued to fill, sand, prime, and sand again the scoop until all lumps and pumps are smooth and shiney. I now draw panel lines on ready for chart pack tape and primer filler to build up to create panel line. The lower cowl i have glued in place making sure the side profile looks correct and then start to fill the gap ready for primer and wet and dry sanding, panel lines and waxing prior to mold being taken directly off plug with a simple tape line to show edge. With the rudder this is more of a experiment but I think it can work. First I filled in between balsa with blue foam and then glassed with 1 oz cloth follwed by a secong coat of resin. Next i will primer fillm and sand very smooth then I will start surface details . Stay tuned...Trent Smith

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    RE: 84 - 2/16/2013 9:17 AM

    trent smith






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    Status: offline Hello again, well since last post I have done a few things. The main thing was to lay up and pull my first fuse from the molds and HOORAY it worked. I first started by spraying a grey automotive 2 pack paint into the mold after wax and pva mold release was first applied. Then I layed a layer of 100gram cloth then a core material called ' corecork' and then another layer of 100gram cloth applied. A layer of heavier 300gram cloth was layed in the forward section to give a bit extra strength around where motor vibration may be present. I then chose to use peel ply followed by breather cloth and then a home made bag from cheap painters plastic drop sheet seeled by gap seal and vacuum was apllied and let set overnight. I then repeated the process on the other side of the mold. Once I had the 2 sides completed I cleaned off any dags of cloth or resin and joined with 25mm glass woven tape and resin and some thickened resin with Q cell and bolted together and waited for it to set. Then like a kid at christmas I popped it open and out jumped A P-51 fuse. I was really happy with the results even though there were a few ting imperfections but these can be avoided with experience on the next one. Cheers Trent.

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    RE: 84 - 2/16/2013 9:19 AM

    trent smith






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    RE: 84 inch P-51 Mustang Plug, Mold and Fuse fabrication

    Hi:
    Sounds like a great project. None of the pictures came through?

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    RE: 84 inch P-51 Mustang Plug, Mold and Fuse fabrication

    Ok now i will try some photos. I have this thread started in the warbird forum and tried to copy and paste the whole thing but photos never worked out.
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    RE: 84 inch P-51 Mustang Plug, Mold and Fuse fabrication

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    RE: 84 inch P-51 Mustang Plug, Mold and Fuse fabrication

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    RE: 84 inch P-51 Mustang Plug, Mold and Fuse fabrication

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    RE: 84 inch P-51 Mustang Plug, Mold and Fuse fabrication

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    RE: 84 inch P-51 Mustang Plug, Mold and Fuse fabrication

    Pics of first fuse fresh from mold
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    RE: 84 inch P-51 Mustang Plug, Mold and Fuse fabrication

    All I can say is "wow", you have done alot of work and it looks like you know what your doing. Only thing I have built from a plug is a cowling and I appreciate what you have put into that mold. I built the 1/5 scale gold kit from T.F. and it's a beautiful plane. Areyou going to make skins for the wings or just how far are you going,? Should be a market for this one, good luck with that aspect should you go there.

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    RE: 84 inch P-51 Mustang Plug, Mold and Fuse fabrication

    Hello Leyroy, thanks for your positive comments. I have put a lot of work into the plug of the fuse which inturn reflects into the finished parts quality. I would hope to get this to a basic kit like American Eagle type kit with glass fuselage, cowl, radiator intake, canopy and foam cores for wings and horizontal stab. Maybe a composite rudder and some basic drawings. Also I just pulled fuse number 2 from the molds. Cheers Trent.
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