RE: Giant Fusion - Prototype Build (Hybrid)  
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RE: Giant Fusion - Prototype Build (Hybrid) - 11/13/2007 12:46:17 AM   
AFSalmon



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From: Beavercreek, OH,
Status: online 		Holy cow Dave you do amazing work. She's looking really nice! Glad to see teh turtle deck came together ok. Guess my CAD work wasn't too shabby for a quick custom job.

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RE: Giant Fusion - Prototype Build (Hybrid) - 11/13/2007 12:46:46 AM   
AFSalmon



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Status: online 		Oh, forgot to mention that CF pipe sure is schweeeeeeettt!

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RE: Giant Fusion - Prototype Build (Hybrid) - 11/13/2007 1:09:07 AM   
martyg



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Status: offline 		Nice!

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RE: Giant Fusion - Prototype Build (Hybrid) - 11/13/2007 2:06:38 AM   
plasticman


 

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From: Xenia, OH, USA
Status: offline 		Thanks guys.....Its com'in together nicely. I started on the cowl: I shaped the foam and have put on 4 layers of cloth so far. I am going to let it dry for a couple of days and see what I have. I'll start on the top deck this week.

David.


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Plasticman

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RE: Giant Fusion - Prototype Build (Hybrid) - 11/13/2007 1:05:24 PM   
AFSalmon



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From: Beavercreek, OH,
Status: online 		Dave, you definately need to take pics of your cowling making process and share with us. That is truly a skill and task not many of us have tried. Did you use white foam to shape the cowl or something more rigid like "rimboard"?

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RE: Giant Fusion - Prototype Build (Hybrid) - 11/14/2007 2:35:57 AM   
plasticman


 

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Status: offline 		Okay....Here is where I am on the cowl. First, I laminated some two inch thick sheets of blue foam. This is construction foam that you can buy at Lowes. Then I cut it to the rough shape in two dimensions: top view and sides. With this very rough outline I started to carve out the shape with a large razor blade. When I got it close to the shape I then moved to sandpaper and finished the shaping. To carve out the air intake and prop area I used a Dremel.

Once I was satisified with the shape I covered the entire mold with low-temperature covering. In this case I used some old Solite that I had laying around. This keeps the Fiberglass Epoxy from soaking into the foam too much. Then, I start with covering the mold with fiberglass cloth. I used .5 oz cloth and put it on with two pieces: one that covered the front of the cowl and then one larger piece that covered all the sides (top, right, left and bottom). I put on four layers of the .5 oz cloth. The Epoxy that I used was EZ-Lam from Aerospace Composites and I thinned it with Isopropyl alcohol. I brushed the Epoxy on with a 2-inch brush.


Also, tonight I added an electronic equipment floor to the inside of the fuse and a throttle servo holder.

David

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Plasticman

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RE: Giant Fusion - Prototype Build (Hybrid) - 11/14/2007 1:04:06 PM   
AFSalmon



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From: Beavercreek, OH,
Status: online 		Dave that is SOOOOO cool! I never thought about using the blue foam. That is certainly a much better choice than bead foam. How are you going to smooth out the outside of the cowling? Just a bunch of sanding I guess? At this rate you will be ready to test fly this bird in a couple weeks.

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RE: Giant Fusion - Prototype Build (Hybrid) - 11/14/2007 4:15:56 PM   
mmattockx


 

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quote:

ORIGINAL: AFSalmon

Dave that is SOOOOO cool! I never thought about using the blue foam. That is certainly a much better choice than bead foam. How are you going to smooth out the outside of the cowling? Just a bunch of sanding I guess? At this rate you will be ready to test fly this bird in a couple weeks.


Mike, the blue foam is a much better choice and can be sanded quite smooth with a bit of care. Add a bit of filler and you have a pretty decent plug to mold over top of. Then some acetone inside and the foam disappears... It is a pretty good way to do one-off glass work. I have also used blue foam for custom wing tip shapes, covered with one layer of 2oz glass.

Dave, sorry for the brief hijack. Now, back to the regularly scheduled programming...

Mark

< Message edited by mmattockx -- 11/14/2007 4:17:01 PM >

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RE: Giant Fusion - Prototype Build (Hybrid) - 11/14/2007 4:24:57 PM   
plasticman


 

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From: Xenia, OH, USA
Status: offline 		Yes, lots of sanding ahead to get it smooth and back into shape. Then, I think I will do a final coat of cloth, a final finishing coat of epoxy, and then prime and paint.

Dave


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Plasticman

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RE: Giant Fusion - Prototype Build (Hybrid) - 11/14/2007 5:45:55 PM   
mcart


 

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From: Waynesville, OH, USA
Status: offline 		Wow, that is looking sweet. I cant believe your putting in all this work for my Christmas gift. Of course, if you dont give it to me I might have to accidentally let your wife know how much all that stuff costs when you come over for Thanksgiving!

< Message edited by mcart -- 11/14/2007 7:36:48 PM >

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RE: Giant Fusion - Prototype Build (Hybrid) - 11/14/2007 7:04:14 PM   
AFSalmon



Posts: 3645
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From: Beavercreek, OH,
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quote:

ORIGINAL: mcart

Wow, that is looking sweet. I cant believe your putting in all this work for my Christmas gift. Of course, if you dont give it to me I might have to accidentally let your wife no how much all that stuff costs when you come over for Thanksgiving!


Uh Oh Dave, sounds like blackmail to me!

Ok, here's a question: why the low heat covering first? I know you wanted to prevent resin from soaking into the foam but it seems the smoothness of your plug would not be as good as the blue foam by itself. Not sure the blue foam would really soak up that much resin and after you dissolve the foam, you could lightly sand any resin buildup off couldn't you?

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RE: Giant Fusion - Prototype Build (Hybrid) - 11/14/2007 7:11:42 PM   
LeeHop



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From: Aurora, OR, USA
Status: offline 		Or spray the foam with latex paint and then wax it with a spray-on wax?

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RE: Giant Fusion - Prototype Build (Hybrid) - 11/15/2007 2:29:43 AM   
AFSalmon



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quote:

ORIGINAL: LeeHop

Or spray the foam with latex paint and then wax it with a spray-on wax?



"Wax on......wax off" Bigga circles young grasshopper.

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RE: Giant Fusion - Prototype Build (Hybrid) - 11/15/2007 3:36:45 AM   
plasticman


 

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quote:

ORIGINAL: AFSalmon

Ok, here's a question: why the low heat covering first? I know you wanted to prevent resin from soaking into the foam but it seems the smoothness of your plug would not be as good as the blue foam by itself. Not sure the blue foam would really soak up that much resin and after you dissolve the foam, you could lightly sand any resin buildup off couldn't you?



I used low temp so that it would not melt the foam. Tonight, I sanded it smooth and added one more layer of cloth. I will put one more finish coat on and final sand. Hopefully I will get lucky and the foam mold will release somewhat. I will remove all that sticks with some acetone.




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