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Large futura prep and painting

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Old 03-14-2012, 01:40 AM
  #226
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Default RE: Large futura prep and painting

Work on the Futura starts tonight, i will be prepping the airframe ready for the delivery of the repair items next week.

After reviewing the photos of all the damaged parts i have been able to ascertain the extent of the damage and that i

will be able to repair her back to the same condition. Tomahawk are kindly supplying a new front section which will be grafted

onto the existing airframe. I will be doing a classic aviation repair on the airframe, i can carry this repair out with confidence as my full time job

is a Aviation Design Repair/Modification Engineer for a large Airline so this repair is 'a walk in the part' for me, it must just take some time, fingers

crossed she will be ready in three weeks.

i will take some photos of the repair on the fuse but will post these at the end.
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Old 03-14-2012, 02:25 AM
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Default RE: Large futura prep and painting

Bring it on Phil...looking forward to this one.

Rob.
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Old 03-14-2012, 04:33 AM
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Default RE: Large futura prep and painting

I hope to have her ready for Classic Jets #50
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Old 03-14-2012, 11:03 PM
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Default RE: Large futura prep and painting

I am so pleased to hear that this plane will be repaired. Well done to Ali for admitting his mistake and also well done to philip for getting on with the repair so quickly.
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Old 03-15-2012, 09:01 AM
  #230
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Default RE: Large futura prep and painting

Started the repair last night, wing delamination and u/c beares sorted. Written off fuel tank back together and all tha damage has been removed from the fuse and both inner and outer surfaces prepared for the new nose section
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Old 03-15-2012, 09:46 AM
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Default RE: Large futura prep and painting

Phil, don't forget to post the pictures and a 'how its done', I for one am interested in your process and skills in this area.

marcs
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Old 03-15-2012, 09:50 AM
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Default RE: Large futura prep and painting


Quote:
ORIGINAL: marc s

Phil, don't forget to post the pictures and a 'how its done', I for one am interested in your process and skills in this area.

marcs
+1[8D]
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Old 03-15-2012, 10:27 AM
  #233
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+2
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Old 03-15-2012, 01:27 PM
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Default RE: Large futura prep and painting

Hi Ali and Phil,

All the best with the repairs!

I am just about to maiden my Futura 2.5.
I will be checking that the Aileron comes up to meet the stick!

This was a lesson I had drummed into me when I learnt to fly gliders many years ago.

Regards, Adam.[8D]

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Old 03-17-2012, 02:40 PM
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Default RE: Large futura prep and painting

Today was a good day, got both fuel tanks rubbed down and fine filled and got a few coats of primer on them, also got the pylons to the same condition, tomorrow I hope to have them painted the base colour 'sand'. A big thank you to Ralle at taylormadedecals for the very prompt delivery of a decals, paint masks and additional paint which arrived this morning.

One tank only had a small dent in the side which was easy to pull out, bond and fill, other was a little worse.

With the second tank there was only about half an inch that joined the two halves together, to join the two halves I lined the inside of one half with thin glass sheet and bonded it to the inside, then slid the two halves together and bonded them using hysol. The area that was missing I filled with another piece of this glass sheet to give the tank a bit of stiffness.





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Old 03-17-2012, 02:52 PM
  #236
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Default RE: Large futura prep and painting

And a few photos of the finished pylons and second tank







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Old 03-18-2012, 01:14 AM
  #237
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Default RE: Large futura prep and painting

Very well done and keep up the good work. Make sure you charge your premium rates on this one
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Old 03-18-2012, 05:01 AM
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Default RE: Large futura prep and painting

Wow this is amazing! You should do a "how to" video, showing step by step instruction of your building techniques.. I'd buy that!
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Old 03-20-2012, 12:22 PM
  #239
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Default RE: Large futura prep and painting

Well some riveting stuff to show you today, the pylons and fuel tanks repaired and now rivetted up, panel lines also done. Rivets were put on using the soldering iron.

Good news Ali messaged me today saying the front section is on its way so should be either late tomorrow or Thursday which is really good news, I hope it's all joined up by the end of the weekend. I will take a few photos so you can see how I have jinxed the two halves.

I will post them at the end to prevent to many questions, they should all be self explanatory.







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Old 03-20-2012, 02:28 PM
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Default RE: Large futura prep and painting



looking very nice indeed

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Old 03-20-2012, 04:24 PM
  #241
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Default RE: Large futura prep and painting

Very sorry for that sad experience ! What a shame after all this work. But after all, that's how we can learn and stay careful after so many models... [:@][:'(]

I will be very interested about how you can cut this fuselage and glue back a new one... This a very high skill rebuild process. We need Docteur House here !
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Old 03-21-2012, 08:07 AM
  #242
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Default RE: Large futura prep and painting

I'm sure I asked Ali for one of those replacement front fuselage sections after I snapped my Futura at Bickley 2011 Managed to glue it back together but its probably the only Futura out there with a distinctly bent nose. Great for knife edge one way but unfortunatley not the other. []

Looking forward to seeing the guide to grafting these sections together...
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Old 03-21-2012, 05:55 PM
  #243
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Default RE: Large futura prep and painting

Even though you are quite handy mate I'm not sure you could have grafted this size nose on to your Futura!
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Old 03-22-2012, 01:23 PM
  #244
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Default RE: Large futura prep and painting

I have heard today that the nose section may arrive tomorrow, fingers crossed I can pick it up and get started on her over the weekend.

Last night I was able to give the tanks and pylons a couple of coats of base sand, I am please with the detail reproduced after the repair.

Next job will be brown and weathering.









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Old 03-27-2012, 01:38 PM
  #245
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Default RE: Large futura prep and painting

Today the front section finally arrived at 4pm, so straight away I started work, first thing was to remove the intakes and trim the nose so she could slide inside. I then mark the final cut lines using the new canopy to line up the new nose. After cutting i pre fitted her to ensure that I had a nice gap all the way round.

Next was the final lining up process, I used small strips of balsa wood cyno'd to the original fuse, I then position the canopy at the rear using masking tape and at the front using the small strips of balsa wood. The new nose was then positioned using the balsa strips and the canopy. Once in position I bonded the nose to a number of the balsa strips, this held the nose while I removed the canopy. I could now get access inside to finish off bonding the balsa strips to the nose. In a couple of places I had to cut slots to allow a slight mismatch.

Once she was full bonded I added a few more balsa strips for added support while I glassed the inside. To prevent all the resin escaping I put masking tape across the gaps. Once completed I started the glassing process.

Tomahawk was kind enough to send some of the layup resin with the nose, I used this to bond the two half together. I bonded across the gap a strip 2.0" wide piece of carbon fibre. When all of the carbon was position and covered in resin I then went over the top with 10onz glass cloth, this was approximately 6.0" wide. When this was completed I added an additional strip of carbon and glass along the keel on the aircraft. I will take some photo of the final lay up in the morning due to the late finish.

What follows is the sequence of photo's through the joining process, enjoy





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Old 03-27-2012, 01:41 PM
  #246
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Some more















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Old 03-27-2012, 01:47 PM
  #247
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And more

































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Old 03-27-2012, 01:57 PM
  #248
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Default RE: Large futura prep and painting

way to go! the extended canopy will help a lot in this rebuilding.. congrats for the great work done so far.

with a bit of luck, next flight will be sweet!



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Old 03-27-2012, 10:39 PM
  #249
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Default RE: Large futura prep and painting

And finally some photos of the lay up joint







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Old 03-28-2012, 12:50 AM
  #250
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Default RE: Large futura prep and painting

Amazing job Phil!!

Is the joint scarfed or is it a straight layup?

Out of all the threads on RCU this one has to be the best in my opinion, keep up the good work Phil.

Adam

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