8'WS PBY-5 Vintage Plans Robert Sweitzer
05-08-2013, 06:12 AM
#151
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RE: 8'WS PBY-5 Vintage Plans Robert Sweitzer
I do all of the Fast & Final be for I do any glassing and then
no more that way all of the goo comes out in the fiber glass bag nice and clean
Here's what I'm up to while waiting for the filler to dry I've made the tops for the floats and I'm trying some rivets and lines on these to see how much detail you
can do w/ this method. If it doesn't come out no great loss I'll add them later in the paint and the tops should fit in side very tight check the progress photos there will be a total of 4 molds for these.
Bruce
no more that way all of the goo comes out in the fiber glass bag nice and clean
Here's what I'm up to while waiting for the filler to dry I've made the tops for the floats and I'm trying some rivets and lines on these to see how much detail you
can do w/ this method. If it doesn't come out no great loss I'll add them later in the paint and the tops should fit in side very tight check the progress photos there will be a total of 4 molds for these.
Bruce
05-08-2013, 06:28 AM
#152
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RE: 8'WS PBY-5 Vintage Plans Robert Sweitzer
An observation, I would get a couple of nylon or wood jaws for your vice. You will get a better flow of your solder with less heat. (Example Bessey Nylon Magnetic Vice Jaw $8.68 @ LOWES)
Nice looking metal work. Those are going to be great floats.
05-08-2013, 06:55 AM
#153
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RE: 8'WS PBY-5 Vintage Plans Robert Sweitzer
Thanks Steve...My torch was set at almost the lowest it will go when I solder the last bit the first parts that that looked like boomarangs were lay on the small sheets had to be heated a bit more. If your refering to heat disapation because of the vice that was minamal.
Bruce
Bruce
05-09-2013, 11:47 AM
#154
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RE: 8'WS PBY-5 Vintage Plans Robert Sweitzer
Well I started to glass one of the float plugs w/ 3/4 oz cloth to see how the details
of the lines and rivets will stand out it looks like it's going to work but really won't
know until it's cast in plaster check the progress photos.
Bruce
of the lines and rivets will stand out it looks like it's going to work but really won't
know until it's cast in plaster check the progress photos.
Bruce
05-09-2013, 01:27 PM
#156
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RE: 8'WS PBY-5 Vintage Plans Robert Sweitzer
Dan NO retracts!!! that's why I started this build I'm scratch building two sets of gear on my other two other builds.
THIS IS A FUN BUILD!
The others are P-38M and a mk.VI Mossie NF.
Bruce
THIS IS A FUN BUILD!The others are P-38M and a mk.VI Mossie NF.
Bruce
ORIGINAL: All Day Dan
Bruce, I don’t recall if you mentioned this or not but are you going to make the PBY in to an amphibian with retracts or use it as a float plane? Dan.
Bruce, I don’t recall if you mentioned this or not but are you going to make the PBY in to an amphibian with retracts or use it as a float plane? Dan.
05-11-2013, 09:05 AM
#157
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RE: 8'WS PBY-5 Vintage Plans Robert Sweitzer
Okay I started the day sanding the first set of float plugs and went over each rivet
hole again.
Then I touched up sanded the second set and put the rivets in on that set and applied the poly and 3/4oz fiberglass cloth.
And then I put the 5th coat of poly on the first set now I'll start making there casting boxes and keep sanding set 2 and get them ready to cast.
Bruce
Then I touched up sanded the second set and put the rivets in on that set and applied the poly and 3/4oz fiberglass cloth.
And then I put the 5th coat of poly on the first set now I'll start making there casting boxes and keep sanding set 2 and get them ready to cast.
Bruce
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05-13-2013, 12:23 PM
#158
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RE: 8'WS PBY-5 Vintage Plans Robert Sweitzer
Anyway Roddie had asked about the rivets sticking out and not in and that would be correctremember I kept punching the holes you will see why in the photos.
I know guys use glue drops to simulate rivets but I tried another method mine are more pronounced but can be sanded down after casting I filled the holes w/ small plastic tube cut about 1/8" long.
Then I sprayed poly w/ my airbrush to help hold them in place while casting.
I also made casting boxes and lined them w/ duct tape it's Christmas tape so excuse the red and white stripes I thought this would be the perfect thing to use up this tape.
I'm trying to get the plugs into the plaster today if possible I know somebody will have some questions after seeing what I'm up to this time so bring them on guys!
Bruce
remember I kept punching the holes you will see why in the photos.I know guys use glue drops to simulate rivets but I tried another method mine are more pronounced but can be sanded down after casting I filled the holes w/ small plastic tube cut about 1/8" long.
Then I sprayed poly w/ my airbrush to help hold them in place while casting.
I also made casting boxes and lined them w/ duct tape it's Christmas tape so excuse the red and white stripes I thought this would be the perfect thing to use up this tape.
I'm trying to get the plugs into the plaster today if possible I know somebody will have some questions after seeing what I'm up to this time so bring them on guys!
Bruce
05-13-2013, 05:25 PM
#159
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RE: 8'WS PBY-5 Vintage Plans Robert Sweitzer
Alright I kept on working and got everything ready to cast the plaster molds and went for it!!
Then I remembered that I didn't WAX the plug
But it turns out you don't even need to WAX or at least this time for methe fiberglass pulled away no problem but the little pieces of plastic tube stayed in place accept a few so I twisted them one at a time and they came right out.
Then it was time for the lids (tops of the floats) these I waxed and they came out easy also w/ one exception there were bubbles under each flat part , this is no problem to get to and fill w/ some Fast & Final once they cure under the heat lamp for a few hrs.
Now I'll get the glass ready so I can poor the resin as soon as there ready because they have to set up for 24hrs be for I can CRACK the molds
Bruce
Then I remembered that I didn't WAX the plug
But it turns out you don't even need to WAX or at least this time for me
the fiberglass pulled away no problem but the little pieces of plastic tube stayed in place accept a few so I twisted them one at a time and they came right out.Then it was time for the lids (tops of the floats) these I waxed and they came out easy also w/ one exception there were bubbles under each flat part , this is no problem to get to and fill w/ some Fast & Final once they cure under the heat lamp for a few hrs.
Now I'll get the glass ready so I can poor the resin as soon as there ready because they have to set up for 24hrs be for I can CRACK the molds
Bruce
05-14-2013, 12:03 PM
#161
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RE: 8'WS PBY-5 Vintage Plans Robert Sweitzer
Alright I had some time this morning so I went ahead and cast the floats
First I cut out three sheets for each mold of 5oz cloth the shape of the floats then three strips for each to cover the sides.
It was fairly easy the hardest part of these was the prep. after waxing I had to go back and clear out the wax from all of the holes.
This is not for people that don't have patience I know during this process I had to punch the holes thousands of timesbut I think the end results will show the hard work.
So now I cant even thinking about touching it until this time tomorrow so have a look at the progress photos.
Bruce
First I cut out three sheets for each mold of 5oz cloth the shape of the floats then three strips for each to cover the sides.
It was fairly easy the hardest part of these was the prep. after waxing I had to go back and clear out the wax from all of the holes.
This is not for people that don't have patience I know during this process I had to punch the holes thousands of times
but I think the end results will show the hard work.So now I cant even thinking about touching it until this time tomorrow so have a look at the progress photos.
Bruce
05-15-2013, 05:38 AM
#162
Senior Member
Thread Starter
RE: 8'WS PBY-5 Vintage Plans Robert Sweitzer
Well it's been 18 hrs. and it's still not cured it's been very cool here for spring and temp. has a great deal on how this resin sets up so I've trimmed the access fiberglass off while it's still soft and placed the molds under the heat lamp should cure in 3-6 hrs now!
So in the mean time I'll go back to working on the brass float retracts.
Bruce
So in the mean time I'll go back to working on the brass float retracts.
Bruce
05-15-2013, 08:02 PM
#163
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Thread Starter
RE: 8'WS PBY-5 Vintage Plans Robert Sweitzer
Not to much to report tonight guys the resin still a bit soft and I'm not cracking these babies until I'm sure it's fully cured so I wait 
but there was a bunch of work on these so it worth the wait.
So in the mean time I started looking at my brass but I really need the floats to find out how long to cut the parts and make there pivots.
So I said the heck w/ it and started packing for my trip to the VA. Beach USA.
Air Show this weekend were camping and going to the show so there's a lot of stuff to pack.
I'll be sure and take a whole bunch of photos to post for you guys we already have our tickets and reservations for the camp ground VA. State park on the beach.
There should be a really big turn out because of the Mossie I heard there bringing a Lancaster down from Canada and a few others here's the planes I know about that will be there.
P51, P40 Corsair, Wildcat, Avenger, B17, B25, PBY, Spitfire, ME262, FW190, ,
FW44J, Hurricane,Yak3 and I heard something about a Swordfish also coming down from Canada.
Bruce
but there was a bunch of work on these so it worth the wait.So in the mean time I started looking at my brass but I really need the floats to find out how long to cut the parts and make there pivots.
So I said the heck w/ it and started packing for my trip to the VA. Beach USA.
Air Show this weekend were camping and going to the show so there's a lot of stuff to pack.
I'll be sure and take a whole bunch of photos to post for you guys we already have our tickets and reservations for the camp ground VA. State park on the beach.
There should be a really big turn out because of the Mossie I heard there bringing a Lancaster down from Canada and a few others here's the planes I know about that will be there.
P51, P40 Corsair, Wildcat, Avenger, B17, B25, PBY, Spitfire, ME262, FW190, ,
FW44J, Hurricane,Yak3 and I heard something about a Swordfish also coming down from Canada.
Bruce
05-19-2013, 07:19 PM
#164
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Thread Starter
RE: 8'WS PBY-5 Vintage Plans Robert Sweitzer
Well alright guys went to the WARBIRDS Over the Beach this past weekend and
Well it rained really hard Friday night after we got our camp and was raining Sat. morning as well but we went to the show anyway.
It looked like a wash out all together but the Rain slowed up while we were looking through the museum and I was able to run out and take a few photos of some of the planes on the tarmac.
A little bit later the sun came out for a short while and the grass runways began to dry in the light wind but they still weren't sure if any planes would fly but they were able to get a few smaller ones in the air.
I'm sorry to say none of the bigger fighters flew but they opened up all of the hangers and let every body look at all of the collection.
I still had a great time we met and talked to a great deal of people that knew about each of the planes history during and after the war.
I won't post all of the photos here but they will be posted on my other threads.
It looked like a wash out all together but the Rain slowed up while we were looking through the museum and I was able to run out and take a few photos of some of the planes on the tarmac.
A little bit later the sun came out for a short while and the grass runways began to dry in the light wind but they still weren't sure if any planes would fly but they were able to get a few smaller ones in the air.
I'm sorry to say none of the bigger fighters flew but they opened up all of the hangers and let every body look at all of the collection.
I still had a great time we met and talked to a great deal of people that knew about each of the planes history during and after the war.
I won't post all of the photos here but they will be posted on my other threads.
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05-20-2013, 04:18 PM
#166
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RE: 8'WS PBY-5 Vintage Plans Robert Sweitzer
Alright I've been back to it and when I left the resin still had not set and when I got back it didn't either!!
I've told you guys I would show you things even if they don't work out and this is one but let's see if we can save it if not then I'll go back and start over.
The only thing I can think happened was I rushed and didn't mix the resin well enough
it was the same that I used for the cowlings and same prportions mixed
SO to try and save the pieces this is what I have done. first I had to just give up on saving the rivets
but that's not a big deal then I took some 3M resin and 2oz cloth and lined the inside of the floats then removed the plaster after the resin had set.
It was very sticky so I pressed all of the 5oz cloth down tight and smoothed baby power on to get it all smooth and remove all of the plaster chuncks.
Then I wiped down the whole outside of the float w/ alcohol and mixed more 3M resin and brushed on a thin coat, after that I mixed in some power to that resin and spread another thin coat now I let it setup it's going to take some sanding and spot putty to make a final finish but it almost always does w/ fiberglass parts.
Bruce
I've told you guys I would show you things even if they don't work out and this is one but let's see if we can save it if not then I'll go back and start over.
The only thing I can think happened was I rushed and didn't mix the resin well enough
it was the same that I used for the cowlings and same prportions mixedSO to try and save the pieces this is what I have done. first I had to just give up on saving the rivets
but that's not a big deal then I took some 3M resin and 2oz cloth and lined the inside of the floats then removed the plaster after the resin had set.It was very sticky so I pressed all of the 5oz cloth down tight and smoothed baby power on to get it all smooth and remove all of the plaster chuncks.
Then I wiped down the whole outside of the float w/ alcohol and mixed more 3M resin and brushed on a thin coat, after that I mixed in some power to that resin and spread another thin coat now I let it setup it's going to take some sanding and spot putty to make a final finish but it almost always does w/ fiberglass parts.
Bruce
05-21-2013, 05:10 AM
#167
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RE: 8'WS PBY-5 Vintage Plans Robert Sweitzer
I’m surprised we don’t hear more about fiberglass failures, I grew up fiber glassing surfboards, and to get the right finished product is an art. There are so many variables (humidity, temperature, mixture of catalyst to resin & prayers to the surfing gods). A good glasser is hard to find. Don’t feel bad, anyone that has done much fiber glassing has had his share of redo’s.
05-21-2013, 10:05 AM
#168
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Thread Starter
RE: 8'WS PBY-5 Vintage Plans Robert Sweitzer
Thanks Steve... come to think of it the day I did the lay up it was cool and humid
and stayed that way for a few days.
I'm trying to save my pieces by sanding and some more resin & Bondo but have given up on the tops, for these I've cut some 1/8" thick 5 ply for those parts.
There would have been some wooden blocks under the fiberglas tops any way
I will maks sleves to capture the legs of the float retrect and they will be screw/ bolted inside the floator something like that.
Bruce
and stayed that way for a few days.
I'm trying to save my pieces by sanding and some more resin & Bondo but have given up on the tops, for these I've cut some 1/8" thick 5 ply for those parts.
There would have been some wooden blocks under the fiberglas tops any way
I will maks sleves to capture the legs of the float retrect and they will be screw/ bolted inside the floator something like that.
Bruce
05-21-2013, 06:58 PM
#169
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RE: 8'WS PBY-5 Vintage Plans Robert Sweitzer
alright the second float is out of the mold and this ones not as bad as the first
so I gave it a quick light coat of the 3M resin and a layer of 3/4oz cloth then a quick sand and finally a coat of Bondo.
The first float has had two coats of high build primer and is looking good
check the progress photos.
Bruce
so I gave it a quick light coat of the 3M resin and a layer of 3/4oz cloth then a quick sand and finally a coat of Bondo.
The first float has had two coats of high build primer and is looking good
check the progress photos.
Bruce
05-22-2013, 03:08 PM
#170
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Thread Starter
RE: 8'WS PBY-5 Vintage Plans Robert Sweitzer
Alright the second float has been shot w/ the first coat of primer and the first has three coats of primer. Never the less I think they'll do just fine so now I can start to move forward to making these retractable floats work.
Bruce
Bruce
05-24-2013, 09:14 AM
#171
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RE: 8'WS PBY-5 Vintage Plans Robert Sweitzer
Alright it's been a couple of days and thought I would give you a progress up date.
So I can move forward I have to get the whole wing ready so I took everything up put the drawings down w/ tape and covered w/ wax paper.
Then I made ready my stringers by sanding them to fit from my rough band saw cuts, I also made to short pieces to fill the gap over the wing tubes and fit the rings I cut earlier around the stringers and wing tube.
The other thing I have done was to drill the rest of the wire chase holes in the ribs along w/ the two alignment dowels toward the LE at the root of the wing.
These I made out of 1/4" poplar and there drilled in about 1" into the center section where the maple blocks for the engine mounts are.
I have also made a 8 small L brackets out of ALUM. these will be the pivots for the brass REC. & ROUND tubes for the float retracts.
Be for I can do anything farther I need to get all of the ribs up R13 glued in and the LE & TE on as well this way I know everything is where it needs be.
Check the progress photos they tell you more than I can say,
HERE WE GO AGAIN THE SERVER WON'T LET ME POST PHOTOS
Bruce
So I can move forward I have to get the whole wing ready so I took everything up put the drawings down w/ tape and covered w/ wax paper.
Then I made ready my stringers by sanding them to fit from my rough band saw cuts, I also made to short pieces to fill the gap over the wing tubes and fit the rings I cut earlier around the stringers and wing tube.
The other thing I have done was to drill the rest of the wire chase holes in the ribs along w/ the two alignment dowels toward the LE at the root of the wing.
These I made out of 1/4" poplar and there drilled in about 1" into the center section where the maple blocks for the engine mounts are.
I have also made a 8 small L brackets out of ALUM. these will be the pivots for the brass REC. & ROUND tubes for the float retracts.
Be for I can do anything farther I need to get all of the ribs up R13 glued in and the LE & TE on as well this way I know everything is where it needs be.
Check the progress photos they tell you more than I can say,
HERE WE GO AGAIN THE SERVER WON'T LET ME POST PHOTOS
Bruce
05-26-2013, 06:27 AM
#172
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RE: 8'WS PBY-5 Vintage Plans Robert Sweitzer
I'm doing some out door things today but hope to get a bit of time this holiday weekend to start gluing the wings.
HAPPY Memorial Day Everybody ! Honor those who gave there lives so we could live free,
Bruce
HAPPY Memorial Day Everybody ! Honor those who gave there lives so we could live free,
Bruce
05-28-2013, 11:52 AM
#173
Senior Member
Thread Starter
RE: 8'WS PBY-5 Vintage Plans Robert Sweitzer
Alright I never had a chance to get any thing built this weekend but today I did
I started by gluing the right wing ribs in place, Then I lay out my LE on a piece of 1/2" x 3" x 36" sheet of balsa they are tapered from 1 3/16" to 13/16" to alow the 3/32" sheeting. This is not how it shows it on the drawing Bob has the sheeting going over the LE when I did the center section this way I had problems so this is why I have changed this. So I was able to get two LE out of that piece of stock w/
a leftover piece to get The TE out of.
I had to glue a splice on the LE a bout 2" long toward the wing tips I had some scrap 1/2" I used for this.
Then I glued the The LE to the ribs using a scrap piece of 3/32" sheeting to hold
the correct spacing to accept the the balsa sheeting that I will add.
Then I glued in the wing tube w/ brown Gorilla glue after wetting everything w/ water using a small brush.
I also made some end caps from a piece of balsa so the wing tube has a stop block they may look big and heavy but there not I've drilled holes in them and ground away most of the bulk.
Check the progress photos.
a leftover piece to get The TE out of.
I had to glue a splice on the LE a bout 2" long toward the wing tips I had some scrap 1/2" I used for this.
Then I glued the The LE to the ribs using a scrap piece of 3/32" sheeting to hold
the correct spacing to accept the the balsa sheeting that I will add.
Then I glued in the wing tube w/ brown Gorilla glue after wetting everything w/ water using a small brush.
I also made some end caps from a piece of balsa so the wing tube has a stop block they may look big and heavy but there not I've drilled holes in them and ground away most of the bulk.
Check the progress photos.
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05-29-2013, 06:19 AM
#174
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RE: 8'WS PBY-5 Vintage Plans Robert Sweitzer
Well I stayed up lat last night and did the sheer webs on the right wing,
for these I used 1/16" thick balsa w/ the grain running vertically on both sides of the
main spars.
Now that the wing is stable I'll start working on the float retract this morning.
Bruce
for these I used 1/16" thick balsa w/ the grain running vertically on both sides of the
main spars.
Now that the wing is stable I'll start working on the float retract this morning.
Bruce
05-29-2013, 11:40 AM
#175
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Thread Starter
RE: 8'WS PBY-5 Vintage Plans Robert Sweitzer
Here's the daily photo progress up date
Last night besides gluing the sheer webs I also glued in the block for the locating dowel.
This morning I started to work on the retract I replaced the wire that comes in the retract w/ a straight piano wire the same size and then I cut a piece of poly tubing that fits the wire and glued it in the center of the leg.
After that I had to remove about 1/8"off the flat side of rib 15.
Then I cut out the shape of the retract unit through rib 13 so it can locate in the middle of that rib. I tried to keep the ply rib 14 in one piece but I will have to cut it so the moving parts will have room to function, and it will get joined to rib 13 w/ solid poplar blocks that the retract will screw into.
I'm also trying to keep both the retract servo and the aileron servo in the same bay so I will only have to have one access hatch on the bottom side of the wing.
I still have a great deal to figure out but you can see where I'm starting to go w/ this float retract.
WELL I DON'T HAVE TO TELL YOU IT WON'T LET ME POST PHOTOS AGAIN
Bruce
Last night besides gluing the sheer webs I also glued in the block for the locating dowel.
This morning I started to work on the retract I replaced the wire that comes in the retract w/ a straight piano wire the same size and then I cut a piece of poly tubing that fits the wire and glued it in the center of the leg.
After that I had to remove about 1/8"off the flat side of rib 15.
Then I cut out the shape of the retract unit through rib 13 so it can locate in the middle of that rib. I tried to keep the ply rib 14 in one piece but I will have to cut it so the moving parts will have room to function, and it will get joined to rib 13 w/ solid poplar blocks that the retract will screw into.
I'm also trying to keep both the retract servo and the aileron servo in the same bay so I will only have to have one access hatch on the bottom side of the wing.
I still have a great deal to figure out but you can see where I'm starting to go w/ this float retract.
WELL I DON'T HAVE TO TELL YOU IT WON'T LET ME POST PHOTOS AGAIN
Bruce