This isn't anything all that spectacular, but it is my first composite project of any size. Up to now my largest project was a rocket powered flying wing which was a one piece composite wing/lifting body about 3' in span. But mainly I have only made canopies, cowls, landing gear, stuff like that. So I'm not totally green, but I still consider myself a novice on this stuff. So I'm looking for any tips, suggestions, etc. anyone might have as I progress.

This is a 2M pattern fuse of my own design. It is loosely based on a blend between a PL Prod Excellence, PL Prod Smaragd, and Oxai Pinnacle. Designed in Autodesk AutoCAD 2004. Fuse without canopy and chin cowl is shown.

I printed out formers at certain stations on a large format laser printer. I then spray tacked these to 1/4" aircraft ply. These were cut out to shape. Holes drilled in the formers to accept 1/2" conduit. Formers were then assembled on the conduit, squared and aligned, and bonded to the conduit with CA. Nose ring was bonded at a 2.5 degree right thrust offset.

I decided on the conduit as opposed to other tubes because it is only $1.79 for a 10 foot stick. It isn't exactly the straightest stuff on earth, but I managed to find a few good sticks at Home Depot (I think the help thought I was nuts as I was checking dozens of tubes to find the really straight ones.) To help ensure I didn't get a twist, I made guides that I bolted to my building table to force all five tubes parallel to each other when bonding the formers.

Formers are cut 1/4" undersize. I plan on sheeting this skeleton with 1/4" balsa, then glass, prime and sand, hence my plug.

Others that have made plugs this way, look OK so far? Thanks in advance. -John