Gilmore Red Lion Build
10-08-2015, 12:19 PM
#552
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Another layer of glass was formed off the plug floor. This layer will become the flange of the blisters.
Once that was cured the footprint of each blister was laid out square to the radius then cut out and sanded to size.
My plan was to use the glass blisters but that did not pan out. By the time they were paired down to fit the flanges the bubble was to shallow. So I will have to make 4 blisters.
Each blister will be made up apart from the plug floor. When shaped to satisfaction they get glued to the floor.
Kevin
Once that was cured the footprint of each blister was laid out square to the radius then cut out and sanded to size.
My plan was to use the glass blisters but that did not pan out. By the time they were paired down to fit the flanges the bubble was to shallow. So I will have to make 4 blisters.
Each blister will be made up apart from the plug floor. When shaped to satisfaction they get glued to the floor.
Kevin
10-09-2015, 11:06 AM
#554
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Sounds like a plan Mike. 
Do you have any of the plane built yet ?
With the flanges made attention was paid to the blisters bumps. They shaped from balsa on the band saw.
Once the plan view was cut. The off fall was save so the elevation could be cut. But first sand paper was stuck to the plug floor and the contour was sanded in. Part of the blister dips over the bull nose. A line was drawn on the plug floor so that the contour was sanded at the correct spot on the blister blank.
Then the side view was laid out and cut.
Then I set about sanding them, the first one took the longest of course with each one moving faster.
At the moment they look a little tall but that should go away once the fillet is in place.
Next the blisters got glassed. I did this now so when the fillet is sanded in, the edge of the blister doesn't get grooved.
Kevin
Do you have any of the plane built yet ?
With the flanges made attention was paid to the blisters bumps. They shaped from balsa on the band saw.
Once the plan view was cut. The off fall was save so the elevation could be cut. But first sand paper was stuck to the plug floor and the contour was sanded in. Part of the blister dips over the bull nose. A line was drawn on the plug floor so that the contour was sanded at the correct spot on the blister blank.
Then the side view was laid out and cut.
Then I set about sanding them, the first one took the longest of course with each one moving faster.
At the moment they look a little tall but that should go away once the fillet is in place.
Next the blisters got glassed. I did this now so when the fillet is sanded in, the edge of the blister doesn't get grooved.
Kevin
10-09-2015, 12:10 PM
#555
I have the main and rear spars built (about 20 pieces each and the ribs dry fitted. I also have the building crutch built. Right now I'm trying to finish a couple of old projects before I start up on the the Ryans again. That probably won't happen until spring. I haven't decided if I want to build then side by side or one after the other. Then I have a quarter scale Globe Swift project and an partial built TF .60 Corsair I got in a trade that needs finishing. And an unstarted TF 1/7 P-51D and TF Sea Fury kits. We won't talk about the other stuff I have in the queue its depressing. I really need to hit the Lotto so I can retire early!
Mike
Mike
10-10-2015, 01:13 PM
#560
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One run, one bug, and ready to sand and polish.
You ran primer ? Why yes I did !
Turns out I only had enough MEKP to catalyze one cup of primer. So needed to get this covered first go.
I sanded though the fiberglass on a small spot on the nose of the far right blister, This raw wood spot showed through as a divot. While trying to fill that divot I acceded the sag rate of the primer. Going to try and sand the flange perimeter and bring back the flange depth without going through. If this don't clean up satisfactorily it will become a 3 bay plug. The bug spot will clean right out.
Other than the sag around the end blister I am very happy with the result. Should be able to polish this puppy up and make a mold soon.
The sag
The bug
Over all
The placement of the blisters on the plug floor is evenly spaced to give as much real estate for layup purposes, front to back is how they will be on the cowl.
I think I got the scale pretty close. Maybe not perfect but better than Gov't work
.
YeeeHaaa Go Cards.
Kevin
You ran primer ? Why yes I did !
Turns out I only had enough MEKP to catalyze one cup of primer. So needed to get this covered first go.
I sanded though the fiberglass on a small spot on the nose of the far right blister, This raw wood spot showed through as a divot. While trying to fill that divot I acceded the sag rate of the primer. Going to try and sand the flange perimeter and bring back the flange depth without going through. If this don't clean up satisfactorily it will become a 3 bay plug. The bug spot will clean right out.
Other than the sag around the end blister I am very happy with the result. Should be able to polish this puppy up and make a mold soon.
The sag
The bug
Over all
The placement of the blisters on the plug floor is evenly spaced to give as much real estate for layup purposes, front to back is how they will be on the cowl.
I think I got the scale pretty close. Maybe not perfect but better than Gov't work
. YeeeHaaa Go Cards.
Kevin
10-11-2015, 11:58 AM
#561
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Feel like I been sanding for 2 days, two 1/2 days anyway.
Sanded up the plug this morning. Was able to unearth the end blister from the globe of primer without burning thru. Yea. Sanded the primer droop out with 320. Then sanded the entire plug with 400. Then 500 sanding sponge, then 1000 sanding sponge. After that it was rubbed out with some semi polishing compound. This left a semi matt very smooth finish. I didn't polish this plug shiny though. Experience has taught me that the PVA mold release gets shiny if laid down well.
Then I back filled the lip edge with model clay so as to keep a clean sharp ridge at this point of the mold. On the first blister mold this edge was just a little bit rough.
So with the sanding done, Wax on Wax off, Wax on Wax off, Danielson. Then PVA.
Exhibit A on the shiny.
Once that was dry. Next came the first layer of jell coat.
Gonna get this bad boy molded up today, YeeHaaaaw
Kevin
Sanded up the plug this morning. Was able to unearth the end blister from the globe of primer without burning thru. Yea. Sanded the primer droop out with 320. Then sanded the entire plug with 400. Then 500 sanding sponge, then 1000 sanding sponge. After that it was rubbed out with some semi polishing compound. This left a semi matt very smooth finish. I didn't polish this plug shiny though. Experience has taught me that the PVA mold release gets shiny if laid down well.
Then I back filled the lip edge with model clay so as to keep a clean sharp ridge at this point of the mold. On the first blister mold this edge was just a little bit rough.
So with the sanding done, Wax on Wax off, Wax on Wax off, Danielson. Then PVA.
Exhibit A on the shiny.
Once that was dry. Next came the first layer of jell coat.
Gonna get this bad boy molded up today, YeeHaaaaw
Kevin
Last edited by Melchizedek; 10-11-2015 at 12:02 PM.
10-11-2015, 04:03 PM
#563
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Say, do you think if we started the " Anal Brotherhood" anybody would want to join ?
Could even make up shirts. Maybe two cheeks with wings on the front.
All molded up, hope all is well under there.
Kevin
Could even make up shirts. Maybe two cheeks with wings on the front.
All molded up, hope all is well under there.
Kevin
10-12-2015, 02:15 AM
#565
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Kevin
Last edited by Melchizedek; 10-12-2015 at 03:08 AM.
10-14-2015, 04:11 PM
#566
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Some material I was waiting for came a few days earlier than expected, so I decided to do a layup.
First, this mold has turned out the best of the seven in quality. Very pleased with this one.
Second, thank God it is a 4 bay'r. By the time I got to layup 9 on the first version, it was feeling like it was never going to end. I'm giddy about 4 at a time.
Kevin
First, this mold has turned out the best of the seven in quality. Very pleased with this one.
Second, thank God it is a 4 bay'r. By the time I got to layup 9 on the first version, it was feeling like it was never going to end. I'm giddy about 4 at a time.
Kevin
10-15-2015, 06:25 PM
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Yes, when things go swimmingly.
When I laid up the version 1 blisters. I was constantly fighting bubbles at the flange rim. The rim is a 90 deg corner, even though it is only about 3/32 thick the glass does not want to lay into it. I overcame this pretty well with a jell coat that was heavy in the corner of the rim. I say pretty well cause I still had some bubbles.
Well with laying up 4 at a time the likelihood of bubbles goes up. Bubbles create voids.
Here is the first layup from yesterday. You can see the damage a bubble creates in pic 2 and 3.
With a little fill these are very serviceable. However, in search of the void free layup a different method was tried.
I saw hornitpilot ( Bob, Welcome back to da shop) use this method with a glass wing layup.
First some parchment paper or equivalent is rolled into a cone like a cake decorator. Then some resin and micro balloons was mixed into a thick mixture and put into the cone. Then the small crevice was filled using the applicator. Then the glass was layed over that.
I got just a little sloppy with the resin/balloon mix. Next time I will use more care.
Kevin
When I laid up the version 1 blisters. I was constantly fighting bubbles at the flange rim. The rim is a 90 deg corner, even though it is only about 3/32 thick the glass does not want to lay into it. I overcame this pretty well with a jell coat that was heavy in the corner of the rim. I say pretty well cause I still had some bubbles.
Well with laying up 4 at a time the likelihood of bubbles goes up. Bubbles create voids.
Here is the first layup from yesterday. You can see the damage a bubble creates in pic 2 and 3.
With a little fill these are very serviceable. However, in search of the void free layup a different method was tried.
I saw hornitpilot ( Bob, Welcome back to da shop) use this method with a glass wing layup.
First some parchment paper or equivalent is rolled into a cone like a cake decorator. Then some resin and micro balloons was mixed into a thick mixture and put into the cone. Then the small crevice was filled using the applicator. Then the glass was layed over that.
I got just a little sloppy with the resin/balloon mix. Next time I will use more care.
Kevin
Last edited by Melchizedek; 10-15-2015 at 06:28 PM.
10-16-2015, 05:38 AM
#570
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Thanks Mike, wish it (idea) were mine. It makes a great spreader. Don't cost nothing either.
Ok, The first 4 keepers are out of the mold and sized up. No bubbles on the rim.
This is the way I will proceed with the remainder of the blisters.
With a batch of keepers I can start bonding them to the cowl. This is where the fun begins. The culmination of a dream (fabrication of blistered cowl).
Kevin
Ok, The first 4 keepers are out of the mold and sized up. No bubbles on the rim.
This is the way I will proceed with the remainder of the blisters.
With a batch of keepers I can start bonding them to the cowl. This is where the fun begins. The culmination of a dream (fabrication of blistered cowl).
Kevin
Last edited by Melchizedek; 10-16-2015 at 05:42 AM.
10-18-2015, 10:12 AM
#573
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My last two Minions (blisters) are in the mold and curing. At this point I have 9 Minions bonded to the cowl. I don't have any structural fast setting epoxy. So going the slow route setting them one at a time using gravity with a weight on top. Letting the epoxy jell then cleaning up the perimeter.
Won't be any pictures to post till they are all on. Later this week.
Kevin
Won't be any pictures to post till they are all on. Later this week.
Kevin
10-20-2015, 02:21 AM
#575
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Thanks Pete,
All the blisters are finally on,
https://www.youtube.com/watch?v=m7TSYimUz3A
https://www.youtube.com/watch?v=-A7SnW6O3tc
Kevin
All the blisters are finally on,
https://www.youtube.com/watch?v=m7TSYimUz3A
https://www.youtube.com/watch?v=-A7SnW6O3tc
Kevin
Last edited by Melchizedek; 10-20-2015 at 04:49 PM.