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recreate canopy - 6/17/2008 11:46:19 AM   
biplane bill


 

Posts: 41
Joined: 7/15/2005
From: Evansville, IN, USA
Status: offline 		I am searching for a solution to recreate a canopy on a 50% airframe. The original was a 1 off and not availible. I have access to a vacume forming machine large enough to pull it from but need to build a plug. The original is damaged but is epoxied back together and is true to shape, just looks bad. How would I go about building a plug? My thoughts were to build a ply box slightly oversize and make a mold with plaster of paris, but I'm concerned the weight of the plaster will deform the original, not to mention the heat involved when that stuff sets up. Perhaps a slow progression of epoxy-glass over the top and then take that to the plaster? Any thoughts?
       Post #: 1

RE: recreate canopy - 6/17/2008 3:24:24 PM   
LesUyeda



Posts: 939
Joined: 10/10/2002
From: San Diego, CA, USA
Status: offline 		I have imbeded smaller canopies in sand for support then fill with plaster of paris. The problem occurs when you have to mix multiple batches of plaster. The first starts to set up, then you pour the second, and it spreads the canopy slightly, and leaves a seam at the juncture. With two or more of you, you could mix and pour continuously. If there is slight spreading on the whole, it should straighten out in the fastening to the air frame.

Les

(in reply to biplane bill)
       Post #: 2

RE: recreate canopy - 6/17/2008 4:46:18 PM   
biplane bill


 

Posts: 41
Joined: 7/15/2005
From: Evansville, IN, USA
Status: offline 		Not a bad idea. That makes a 1 step process to a plug. I had assumed I'd have to pull a mold and then a plug from that. That might just work. Thanks

(in reply to LesUyeda)
       Post #: 3

RE: recreate canopy - 6/17/2008 11:16:55 PM   
fritzke


 

Posts: 852
Joined: 1/3/2002
From: Saint Paul, MN, USA
Status: offline 		I have had good luck with small canopies filling them with "Rock Hard" water putty.
For a big canopy, I would support it in a box of sand as Les suggests and carve
a rough foam plug that is about 1" smaller all around than the inside of tha canopy.
Then fill 1/2 way with Rock hard, insert the plug, and top it off if it did not
have enough. The foam is to reduce weight and use less putty.
Just watch for air bubbles. Hold the foam plug down until it sets. A large
batch will take quite some time to hydrate fully. (days, perhaps)
Clean it up, attach to a hardwood base and have at it on the vacuum table!
Dave

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< Message edited by fritzke -- 6/17/2008 11:23:26 PM >

(in reply to biplane bill)
       Post #: 4

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