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All Composite 1/7th P-40E Mould Build

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Old 05-14-2011, 01:07 PM
  #326
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Default RE: All Composite 1/7th P-40E Mould Build

Thanks Steve, that F4U wing is providing some serious motivation over here.
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Old 05-15-2011, 06:18 PM
  #327
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Default RE: All Composite 1/7th P-40E Mould Build

Just a post of some roughed in clay work. Slow going, but all part of the plan I'm afraid.






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Old 05-15-2011, 07:10 PM
  #328
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Default RE: All Composite 1/7th P-40E Mould Build

Impressive framing.

In a few months we are going to do a composite Arado 243 EDF. When we do it, I'll post the molding methods we use. Will save you a lot of time and material on your next one if you do this again.

Steve
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Old 05-15-2011, 08:06 PM
  #329
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Default RE: All Composite 1/7th P-40E Mould Build

That would be great Steve. I'll be looking forward to watching along for sure. To be honest, I could've wrapped this up a long time ago with a glue gun and some coroplast pillars to hold up coroplast flanges, but that wouldn't be much fun would it? ;D

Actually, here's a story. When I moved last month, I got a new box-spring from a buddy because my last one was a sheet of 1/2 ply and some 2X4's across the bed frame. So I salvaged the desk from a junk pile, and I built what you see on top of it with bits of my bed. I moved the MDF sheet twice: both times to new cities. I've moved this P40 project 5 times now over 6 years!! lol
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Old 05-16-2011, 03:27 PM
  #330
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Default RE: All Composite 1/7th P-40E Mould Build

Ongoing clay work...here you can see that there are still a lot of little cracks and crevices to fill - one day at a time - this stuff is worth the extra effort later on





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Old 05-16-2011, 08:15 PM
  #331
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Default RE: All Composite 1/7th P-40E Mould Build

WOW, wish I knew where you were going with this.
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Old 05-17-2011, 06:02 AM
  #332
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Default RE: All Composite 1/7th P-40E Mould Build

Somewhere to Pry

I will leave the clay in these pry locations when I flip it over and mould the upper flanges. This will give a nice spot to get the crows foot into when separating the finished upper and lower mould sections. I've tried to target potential problem areas while placing them around the periphery.




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Old 05-17-2011, 08:30 AM
  #333
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Default RE: All Composite 1/7th P-40E Mould Build

1/4"-20 Flange Bolt Thread Inserts

Be careful not to over tighten the screws. Just pull them down flush.



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Old 05-17-2011, 12:19 PM
  #334
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Default RE: All Composite 1/7th P-40E Mould Build


[quote]ORIGINAL: Slow Low

That would be great Steve. I'll be looking forward to watching along for sure. To be honest, I could've wrapped this up a long time ago with a glue gun and some coroplast pillars to hold up coroplast flanges, but that wouldn't be much fun would it? ;D


For me, I have done too many for this part to be fun. For us the fun parts is getting a flying one out of it. Over and over in a very short period of time

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Old 05-18-2011, 07:50 AM
  #335
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Default RE: All Composite 1/7th P-40E Mould Build

Bring it on...if you've got clay, I've got all dang day!

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Old 05-19-2011, 10:19 AM
  #336
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Default RE: All Composite 1/7th P-40E Mould Build

Yes folks, it was absolutely free afterall!

I'll post a link to the iso file once I get it ripped...

...and here's a supplies link that looks pretty good too

http://www.miapoxy.com/

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Old 05-19-2011, 10:49 AM
  #337
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Default RE: All Composite 1/7th P-40E Mould Build

Looking forward to seeing this video. May have to incorporate this into my manufacturing class somehow.
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Old 05-19-2011, 01:11 PM
  #338
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Default RE: All Composite 1/7th P-40E Mould Build

haha - ya you could use it as an example of a labour intensive process that should be moved offshore....LOL

Every time I go to use this mould and I don't have tighten a hundred nuts and washers onto all those bolts, I'm gonna grin from ear to friggin' ear! Just set the clutch nice and loose on the driver and give those 1/4" bolts hell. These thread inserts are going to save so much time it's not even funny.




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Old 05-19-2011, 01:12 PM
  #339
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Default RE: All Composite 1/7th P-40E Mould Build

Every time I go to use this mould and I don't have tighten a hundred nuts and washers onto all those bolts, I'm gonna grin from ear to friggin' ear! Just set the clutch nice and loose on the driver and give those 1/4" bolts hell. These thread inserts are going to save so much time it's not even funny.




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Old 05-19-2011, 08:04 PM
  #340
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Default RE: All Composite 1/7th P-40E Mould Build

Looking great man!!!!! Like the concept, I think I know where you're going and I like it. Great time saver. Thanks for the tip on the CD, got mine too.
My project is on hold for baseball right now. End of the high school season with plenty of rain make-ups and umpiring tournaments this weekend and next weekend. I will be watching this with great interest.
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Old 05-21-2011, 01:48 PM
  #341
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Default RE: All Composite 1/7th P-40E Mould Build

These are garage door hinges. I had them laying around from a past project and won't be needing them. I thought this might be a good opportunity to try something new and hinge the two main sections of my wing mould. If it doesn't work out, I will simply remove the hinge pins. I will align their axes with the laser level to give it the best shot at working since they can't simply be mounted flat against the angled back wall.

It's the classic risk vs reward. The question is - are yours big enough to get an angle grinder that close to 3 years work?

I'm not finished cleaning up yet but I needed a break, so here's some pics for today.






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Old 05-22-2011, 06:32 AM
  #342
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Default RE: All Composite 1/7th P-40E Mould Build

These hardwood blocks were $0.50 ea at the woodshop supply store.

Here's their website. They have lightweight ply too...

www.workshopsupply.com

Notice that I've set the hinge pins to level when the blocks are placed on the mould face where they will become part of the finished mould base.


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Old 05-22-2011, 02:16 PM
  #343
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Default RE: All Composite 1/7th P-40E Mould Build

So the hinge pins are level, at the same height, and in the same plane. Hopefully this will work because it will take what is really an awkward two person job and make joining the bulky clam sections a one handed operation. There's still some play in the end because I can shim the hinge plates on the hardwood should need be to get things finalized.



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Old 05-23-2011, 03:31 PM
  #344
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Default RE: All Composite 1/7th P-40E Mould Build

So this is pretty much the mould form completed and ready to cast. I will now go over everything with a fine tooth comb and make sure all the clay is finished off properly.

Once I've laid the main lower section in the formers, they will need to be removed. The clay blocks around the top will just give me somewhere to get between the newly cast mould face and the white board. The formers are very close to the finished plug and we don't want to be trying to force something in the seam to pry the board away from the plug in order to carry on to the second mould section. (main upper) Just dig out the clay and there'll be a nice place to GENTLY pry off these white board formers.

The recesses around the perimeter of the base will also provide a little rigidity but that's not really why I did it.

I've also added two air ports in the wheel bays. They're held in place with clay. Just before laying up a part in the mould I will fill the hole with some clay and glass over them. Once the part has cured I'm hoping that a short blast of air in this location will free the part from the mould. It's the deepest spot in the mould, and it's a flat face at the bottom of a tightly controlled cylindrical form....we'll see....







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Old 05-26-2011, 12:21 PM
  #345
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Default RE: All Composite 1/7th P-40E Mould Build

Almost forgot to fill the wing mounting holes...added cavities in the mould at the aileron trailing edges too. The empty cavity just outboard of the inboard hinge (hmm...clear as mud eh?) will provide a place to feed the control rods from the bellcranks during assembly.

Oh, and a quick pic from the couch of all the pieces that I have moulds for, all duct taped together - motivation....



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Old 05-26-2011, 12:22 PM
  #346
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Default RE: All Composite 1/7th P-40E Mould Build

Almost forgot to fill the wing mounting holes...added cavities in the mould at the aileron trailing edges too. The empty cavity just outboard of the inboard hinge (hmm...clear as mud eh?) will provide a place to feed the control rods from the bellcranks during assembly.

Oh, and a quick pic from the couch of all the pieces that I have moulds for, all duct taped together - motivation....



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Old 06-13-2011, 11:36 PM
  #347
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Default RE: All Composite 1/7th P-40E Mould Build

Once I have progressed to some of the heavier cloth layers in the layup of this main lower mould section, I will lay this straw conduit down on a tacky surface and continue to lay cloth up on top of it. All of the joints have been sealed with clear tape to keep the resin out. I will mould a pipe union into the end faces so that I can screw taps onto each end of the mould.

By running hot tap water through the mould face, I hope to have a means for controlling the time/temp curve for the cure and tool cycles. I should be able to reduce the cure time to some noticeable effect with only tap water to a maximum of about 140 deg. fahrenheit or about 60 Celcius.

To my estimation, this would represent the home hobbiest's best chance of approaching any sort of idealized tool utilization rate while maintaining a moderate capital investment.




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Old 06-14-2011, 06:41 AM
  #348
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Default RE: All Composite 1/7th P-40E Mould Build

Interesting idea.

We use a small "hot box" with space heater.

The only concern I would have is the surface coat. Although you mentioned the surface coat material a few posts back, if voids begin to form around or near the straws, you may loose the most important part of the mold. The surface coat when pulling parts.

And later, I have noticed for us, no one will see the mold, only the quality of the part. Fit, finish, detail, weight,durability, framing in wing.

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Old 06-14-2011, 06:46 AM
  #349
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Default RE: All Composite 1/7th P-40E Mould Build

Some additional motivation. A pic of our Zero. This model is around 15 years old. I have yet to build it. Now with today's electrics, might be time to pull it out of storage.

51"span A6M5.

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Old 06-14-2011, 07:03 AM
  #350
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Default RE: All Composite 1/7th P-40E Mould Build


Quote:
ORIGINAL: SCALECRAFT

Interesting idea.

The only concern I would have is the surface coat. Although you mentioned the surface coat material a few posts back, if voids begin to form around or near the straws, you may loose the most important part of the mold. The surface coat when pulling parts.


Steve
Hi Steve, this is really just a trial with something new. Recycling the straws was the biggest risk. There will be 2 layers of light weight woven fabric, and also a layer of surface veil over 2 coats of the silicon carbide impreg surface coat Steve.

About no-one seeing the mould - I will see it every day, and that's the only person that matters.

Just a note to those who would try a heavier hose or copper or pvc pipe etc. approach: I used the thin walled plastic straw for several good reasons.
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