RCU Forums - View Single Post - Devils cheeks.........How do you make them.
Old 06-13-2002 | 05:24 AM
  #9  
Cajuncharley
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From: South, LA,
Default Devil's cheeks

It is very easy to make your own, tailored to suit the size you need. First cut out the hole in the cowl to give adequate clearance needed. Then draw a teardrop shape where the cheek will attach to the cowl. Use this as a pattern drawn on 1/8th or 3/16th balsa. Then stack (glue) these to the thickness (height) needed, such as 3/4th of an inch. Then sand the glued stack to the shape you want. The lamination of the stack will give you a sort of contour lines to make sure it shape is proportional. Once the mold is shaped to your liking, glue it on a 1/2 or 3/4 dowel or similar stick to use as a handle about 4 to 6 inches long. Then attach the handle to a block or hold it in a vise. Get a couple of latex (disposable) gloves. Cut out a reasonable flat part of the latex and pull it over the mold and wrap it with masking tape over the mold, making sure it has no wrinkles on the surface. With slow dry epoxy, put 2 layers of medium fiberglass cloth over the mold, and one fine layer. Saturate the cloth, and then get a bag of party balloons. Blow up the balloon and press it down over the mold slowly letting the air out of the balloon as press it down over the mold, over the edges of the mold . The balloon will then force the cloth against the mold. After the epoxy cures, trim the edges to mate with the hole in the cowl, with about 1/8th of an inch overlap. Then use small strips of cloth to epoxy the cheek from the inside of the cowl. It is much easier than it sounds. It is relatively inexpensive and the results are well worth it. Much more difficult to describe in writing than to actually do!