ORIGINAL: marc s
While the Aeropoxy dries joining the ducts to the intake mouldings I thought I would show you how I join two home made tank halves.
The tank is for the smoke fuel and I first made a balsa plug, covered this in glass cloth, primed, sanded and eventually a friend made two mould halves. Joining these in the mould is not easy so I started off with two halves...
The problem joining edges like this is there is no support for the edges as they butt up so my fix is to sand around the inside edge, about 10mm deep will do, then sand the outside along the edge maybe 20mm or so in, clean with Acetone or similar. I cut up strips of thin FR4 or 'polyply', sand and clean these off, then taking lengths to suit the inside edges of the tank clamp lengths inside the tank so half of the FR4 is proud of the edge, thin cyano is fed under the inside edge - it wicks in well. Once set remove the clamps and run more cyano along the edges to make sure the strip is well adhered.
Once you have done this all round you can pop the other half on, the FR4 will give you the lip from which to glue the halves together, again thin cyano wicked in will do a good job, kick it and leave for a few minutes to go off totally.
When done all round sand the joined faces, clean off and then apply a good few layers of glass cloth, working with some thin strips to start and then wider ones over the top. I tend to use light cloth and apply more layers, possibly up to 6 in total. Once dry a quick sand to clean up and check for leaks.......