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  1. #101
    fredo's Avatar
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    As you can see, I started making my latex mould. First I made a seam from sticky foam secured by pins then I filled up all small gaps with clay and started brushing the latex. The problem with this method is, it takes too long 'cos every layer needs to dry thoroughly so after about 20+ layers, I will have to put plaster on top of it in order to support the shape. Ok, this is what theory says. Again, this is my first attempt making pilot, so I have no idea what the end result is going to be. If anyone of you have done this before, please don't hesitate to contribute some ideas. I have also mounted my DA50 and started playing with shims in order to create right thrust (about 2 degrees) The plan doesn't show one but I'm sure this can only benefit. So, while I had it in place I decided to start making header for my pipe. I have silver soldered one piece but found out I'm missing straight bit. So, this has to go on a side for a short while.
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    Last edited by fredo; 03-31-2014 at 03:18 AM.

  2. #102

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    Art Chester had a moustache. You could try 'slicking' the pilot and pulling a polyester resin mold from it in halves. Then use Smooth-On.com products for the item.

  3. #103
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    He has a moustache already. My plan is to finish off the other half with latex and then make a plaster shell (also in two halves)on top of it, to keep it in shape. Once, I remove shells and peel off the latex, I will end up with two assembled halves. I just don't know how will polyester or epoxy resin behave in contact with latex.

  4. #104
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    Here is my latest effort. I have finished the header for ES pipe. I had to re-do it as my first attempt was touching the cowling from inside. Definitely didn't like that. This one runs backwards first, rather than down. I also started making a small compartment with a hinged door for my switches. Next I made bottom firewall cover, which will be screwed by 6 screws. It will have a hole in the centre for the header to connect the pipe. The canopy...as you can see it needs a few coats of primer as well as filler and a lot of sanding. The pilot is doing fine, I have removed shims and started latexing the other half. Things are happening....happy days
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  5. #105
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    Hi folks, I'm getting headaches with my pilot figure. It wasn't very successful and the amount of time I spent with it , just didn't pay off. I made 3 hopeless attempts to make my pilot using my made up mould. And as most of you probably suspected it wasn't that easy. I tried 3 different materials. First one was fiberglass resin, then epoxy resin and finally expanding foam. Epoxy resin came out with few holes ( my fault) fiberglass resin (very smelly stuff) came the best and expanding foam was a bit of a joke. It just kept expanding for a half a day or so and after 3 days of curing finally removed my mould and had a bid of a laugh. This guys head just shrunk so badly that he ended up looking more like a drug user rather than a healthy pilot. Anyway, I tried to make most of what I have and started painting my best pilot. Also started doing wing spars as you can see. Well, this plane is not going to see skies as I predicted, so I better not doing any time estimations.
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  6. #106

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    Looks pretty good to me Fredo. you may want to try epoxy with lots of micro balloons.

    Calvi
    Ultra Sport Brother # 144

  7. #107
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    Yes Calvi, I should've tried microbaloons. Oh well, maybe next project. I'm not really happy with results but I'm moving on. I made some repairs to it before painting and it actually looks quite reasonable. I'm done with pilot. I finished wing struts and I'm now concentrating on wing fairing that partially covers the strut attachment to the wing.

  8. #108
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    Here is my wing strut fairing in making. I had to make this before I cover the wing, because I need to install small pieces of ply for the screws to hold it. Finally I cut the wing ailerons. That was pretty straight forward. Temporarily I glued the ailerons with 2mm spacing to the wing, so it can be shaved to shape and sanded.
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  9. #109
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    More progress, finished off mounting of the wing strut fairing and apart from playing with aileron hinging, clevis mounting, etc.. I already started covering. I'm using "sig coverall" with dope.
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  10. #110

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    Fredo,
    The Jeep is really looking good! Did you make up the exhaust flange yourself for your custom exhaust?
    Barzini

  11. #111
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    Hi Barzini, I bought small bits in DA shop but did all cutting and silver soldering myself, so the header tube faces exactly where It needs. The length is about 12". I don't know how es composite pipes perform, so the total length still may have to be changed. For me, it's all trial and error. . Do you still have your jeep?

  12. #112

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    Yes I do still have it!Name:  Nl30925.jpg
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  13. #113

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    Actually I have two now.Click image for larger version. 

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  14. #114
    fredo's Avatar
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    Great to see! Is the second one from the kit?

  15. #115

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    Its from a coverite kit.About 35 years old!

  16. #116
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    ..and still going strong

  17. #117
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    Quote Originally Posted by barzini View Post
    Its from a coverite kit.About 35 years old!
    barzini, how did the build go with the Coverite Kit? I had problems with gaps between the wing leading edge and the rib tips, on two Coverite models. Everything else went together fine.
    Crash, what crash. This is my new kit.
    Carl Goldberg Ultimate Brotherhood #102

  18. #118
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    Some more covering done. I have also assembled UC and sprayed with primer.
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  19. #119

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    Looks sweet, can't wait to see it completed!

  20. #120
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    If you can keep going at this pace, a maiden might not be that far away
    Crash, what crash. This is my new kit.
    Carl Goldberg Ultimate Brotherhood #102

  21. #121
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    Funny you say that, everytime the covering job starts, it makes me feel the completion is somewhere nearby...only to make me realise how much more is still to be done. At the moment I'm in a dilema how to do stitching imitation. All scale guys have their own methods. I can go either easy way using pva glue humps directly over the ribs or laying lightweight strips using dope and pva glue for humps on top of it....just a thought but this takes a lot longer.

  22. #122
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    I had visitors from overseas for 2 weeks, and couldn't do much building but here is some update. Everything is now covered and I've been smelling dope for past few days ...horrible stuff.
    All covered bits will receive 3 coats of dope, to fill the weave. I'm working on the small compartment door for my switches. I have a small magnet, so I figured I could use that for locking. Also I have glued phenolic horns to all control surfaces. Next, I'll give it a light sand and will paint it with acrylic primer 2 coats with the light sand again in between, using fine steel wool.
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  23. #123
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    Guys, I need help. Does anyone know the colour of the number 15 on the side of the fuse? I think I've read somewhere it's gold but I'm not so sure.
    http://www.flickr.com/photos/kemon01...5saJgg-5sf5Gu/

  24. #124
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    Here is my latest effort. I primed the whole plane with household acrylic 3 in 1 paint, slightly diluted. Sanded lightly and started with stitching imitation. I'm cheating this one as you can tell. It's not exactly how it's normally done but I decided to keep it simple and not going into too much detail. This is going to be a plane for fun flying after all and not for scale competitions. ( I'm nowhere near in that level, skill- wise.) Also, I have started working on fitting the canopy as well as painting and made a raised riveted panel in the back of the fuselage.
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  25. #125

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    Quote Originally Posted by fredo View Post
    Guys, I need help. Does anyone know the colour of the number 15 on the side of the fuse? I think I've read somewhere it's gold but I'm not so sure.
    http://www.flickr.com/photos/kemon01...5saJgg-5sf5Gu/
    You are right, in 1935 it was gold, also the license number. On the wing it is black. In 1936 it was the number "3" in gold with black outlines. Hope that helps. Like your build, currently I am about building my own design with 69" span and fiber fuselage. A very old project (30 years or so) ...


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