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Old 08-25-2006 | 11:30 AM
  #84  
Lou Melancon
 
Joined: Oct 2002
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From: Cumming, GA
Default RE: PRIMUS Build

Raineday,
That is an amazing airplane. I can't believe he did that. Way too much time on his hands.

Doculam has a very agressive adhesive, I don't think you need to add anything to it to get a really strong bond. It activates at about 200 degrees but works best at 225-250. At 300 degrees it will shrink so hard it will warp open structures. I had planned to cover the open bays of the wing with doculam then overlay silk. When I changed from dope to two part epoxy it made sense to just paint the clear mylar. You need to use 600 grit to rough up the doculam over open wing structures as anything coarser will cut through (ask me how I know, and how many times I sanded through till I learned my lesson!!!).

This is the first bird I've painted with epoxy in a long time. I would not have doped the bare balsa if I'd know how well the doculam would fill the grain. Also the doped balsa surface prevents air from bleeding out from under the doculam, so you have to be really careful about getting bubbles under the film. Next time I'll prep the wood, apply doculam, then prime and sand out.

KlassKote two part epoxy is a very nice product. The paint masking was done with 3M fine line tape which I found at a NAPA parts store. Get the blue version and not the green, it goes around curves much easier. I used 1/8", 1/4" and 1/2" to mask the plane. The canopy was masked with Bob Dively liquid masking film. The fillets on the rudder/stab and canopy were made from a two part light sandable epoxy from Aircraft Spruce and Specialty called Aerofil, the touched up with light weight spackle.

To apply the KlassKote I used an inexpensive HVLP touch up gun from Harbor Freight and a Badger airbrush. The KlassKote was mixed one part catalyst to color and reduced 6/1. Pressure was 25 lbs psi. Higher pressures work but don't flow out as well.

Doculam is available in 500 foot rolls but you have to buy two rolls minimum. I bought 24" X 500' by two rolls and the cost with shipping was about $40. Enough for the next few hundred planes I build.

The rudder, elevator, throttle servos are already inside the fuse, and the tank is mounted. Once clear coating is finished I will bolt in the HP .61 Gold Cup, install aileron servos, install all control horns and pushrods, put in the receiver and battery then go fly. Should be fun.