My Wood & Foam Bridi UFO Build
10-30-2011, 12:12 PM
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RE: My Wood & Foam Bridi UFO Build
Thanks Guys! 
More sanding & shaping of the fuselage this weekend!
I managed to get the rudder cable exits looking a little better than they were. Still have some filling and clean up work to do on both the rudder and elevator exits though.
As was done for the chin block, I made a See Temp pattern for the front portion of the top block and the curve was marked on both sides of the fuselage. Most of the excess material was sawn off using a 1" X-acto razor saw. Much faster than planing. It was then block sanded using 80 grit paper.
Again I used masking tape along the length of the fuselage sides to act as sanding guides. I also added a couple layers of 1/8", 3M Fine Line Masking Tape to act as a center line guide. This was helpful in keeping things symmetrical while sanding with 80 and 120 grit paper.
The next step is to clean up around the engine compartment so the engine can be installed.
RG [8D]
More sanding & shaping of the fuselage this weekend!
I managed to get the rudder cable exits looking a little better than they were. Still have some filling and clean up work to do on both the rudder and elevator exits though.
As was done for the chin block, I made a See Temp pattern for the front portion of the top block and the curve was marked on both sides of the fuselage. Most of the excess material was sawn off using a 1" X-acto razor saw. Much faster than planing. It was then block sanded using 80 grit paper.
Again I used masking tape along the length of the fuselage sides to act as sanding guides. I also added a couple layers of 1/8", 3M Fine Line Masking Tape to act as a center line guide. This was helpful in keeping things symmetrical while sanding with 80 and 120 grit paper.
The next step is to clean up around the engine compartment so the engine can be installed.
RG [8D]
11-06-2011, 01:30 PM
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RE: My Wood & Foam Bridi UFO Build
Got the engine compartment squared away today!
Once I had the engine in, I noticed that the standard header was pretty close to the fuselage. Close enough that the pipe would end up angled outward quite a bit, which I don't want. It looks like a dog's hind leg that way. So, I ordered a new long bend header from Tower. I'd like to keep the pipe as close to the fuselage as reasonable and still keep it nice and straight.
Next up are the wing fillets. [X(]
RG
Once I had the engine in, I noticed that the standard header was pretty close to the fuselage. Close enough that the pipe would end up angled outward quite a bit, which I don't want. It looks like a dog's hind leg that way. So, I ordered a new long bend header from Tower. I'd like to keep the pipe as close to the fuselage as reasonable and still keep it nice and straight.
Next up are the wing fillets. [X(]
RG
11-12-2011, 09:04 AM
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RE: My Wood & Foam Bridi UFO Build
Almost forgot this little detail.
Something I like to incorporate into most engine compartments is a small drain hole. This hole allows any fuel and oil that might accumulate to drain out.
I just use a short piece of 1/8" diameter brass tubing that's glued in place with 30 minute epoxy. On the inside of the engine compartment I set the tube flush with the surface of the balsa. On the outside of the fuselage the tube is just below the surface of the wood to allow for any finish sanding that will need to be done.
RG [8D]
Something I like to incorporate into most engine compartments is a small drain hole. This hole allows any fuel and oil that might accumulate to drain out.
I just use a short piece of 1/8" diameter brass tubing that's glued in place with 30 minute epoxy. On the inside of the engine compartment I set the tube flush with the surface of the balsa. On the outside of the fuselage the tube is just below the surface of the wood to allow for any finish sanding that will need to be done.
RG [8D]
12-04-2011, 09:43 AM
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RE: My Wood & Foam Bridi UFO Build
Thanks Phil!
I've been working on the wing fillets and for some reason it always takes me forever to get them done!
The plans call for 1/32" plywood to be used for the fillet base, but I opted for 1/64" ply instead because it bends easier.
To glue the ply bases in place I first wrapped the wing with waxed paper and loosely bolted the wing to the fuselage along with the ply bases. I made sure the bases were lined up properly and then tightened the wing bolts to hold everything in place. I then laid down a small fillet of 30 epoxy in the corner between the fillet bases and fuselage sides. The epoxy was then heat slightly with a heat gun. The application of heat causes the epoxy to become water thin and it wicks right into the joint. Any excess glue was wiped up. This method is much easier than applying glue to the joint first and then trying to bolt the wing on and have the plywood sliding around all over the place and making a mess.
Once the epoxy was cured the main part of the fillets were re-enforced with tapered balsa triangles.
The rear part of the fillets, behind the wing, did not bend the way I had hoped they would, so I ended up cutting them off flush with the trailing edge of the wing and gluing them on as separate pieces. They were glued parallel to the bottom of the fuselage using the same method as I mentioned above. I also added a small micro balloon fillet to the bottom side to give them a little more strength while the rest of the work was being done. These areas were also re-enforced with tapered balsa triangles on the top side.
For the bottom side of the fillets I decided to go with balsa instead of filler. These will be sanded to shape after the main part of the fillets have been completed.
For a little extra peace of mind I added a couple small pieces of 2 oz. glass cloth to the top side of the fillets where where they had been cut apart. The filler material that I will be using is considered to be non-structural so this was done to hopefully prevent any cracks that might develop in the future due to vibration.
RG [8D]
I've been working on the wing fillets and for some reason it always takes me forever to get them done!
The plans call for 1/32" plywood to be used for the fillet base, but I opted for 1/64" ply instead because it bends easier.
To glue the ply bases in place I first wrapped the wing with waxed paper and loosely bolted the wing to the fuselage along with the ply bases. I made sure the bases were lined up properly and then tightened the wing bolts to hold everything in place. I then laid down a small fillet of 30 epoxy in the corner between the fillet bases and fuselage sides. The epoxy was then heat slightly with a heat gun. The application of heat causes the epoxy to become water thin and it wicks right into the joint. Any excess glue was wiped up. This method is much easier than applying glue to the joint first and then trying to bolt the wing on and have the plywood sliding around all over the place and making a mess.
Once the epoxy was cured the main part of the fillets were re-enforced with tapered balsa triangles.
The rear part of the fillets, behind the wing, did not bend the way I had hoped they would, so I ended up cutting them off flush with the trailing edge of the wing and gluing them on as separate pieces. They were glued parallel to the bottom of the fuselage using the same method as I mentioned above. I also added a small micro balloon fillet to the bottom side to give them a little more strength while the rest of the work was being done. These areas were also re-enforced with tapered balsa triangles on the top side.
For the bottom side of the fillets I decided to go with balsa instead of filler. These will be sanded to shape after the main part of the fillets have been completed.
For a little extra peace of mind I added a couple small pieces of 2 oz. glass cloth to the top side of the fillets where where they had been cut apart. The filler material that I will be using is considered to be non-structural so this was done to hopefully prevent any cracks that might develop in the future due to vibration.
RG [8D]
12-04-2011, 09:45 AM
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RE: My Wood & Foam Bridi UFO Build
The wing cut out shown in the side view on the plans is for the root rib and doesn't allow for the wing taper, so a couple small balsa filler pieces were necessary to fill the gap between the fillet bases and fuselage sides near the leading edge of the wing.
In the past I've always use SIG Epoxolite to make wing fillets. The Epoxolite is a good product but is a real bugger to sand! For this project the filler I used is [link=http://www.westsystem.com/ss/]West System[/link] #410 Microlight Fairing Filler with their #105 resin and #206 hardener. I've been wanting to try West System epoxy for several years and decided it was time. I've heard a lot of good things about their products.
The epoxy and filler were mixed as per the instructions to a peanut butter consistency and applied to the fillet area. To shape the fillet I used a vinyl decal removal tool called the [link=http://www.lidcoproducts.com/Chizzler_Squeegee.cfm]Chizzler[/link]. It has the perfect shape, and worked well. Much better than my inconsistent finger!
After the filler had cured I noticed a few air bubbles. Not sure if this is normal for this product or if I did something wrong. Most likely it was something I did! Either way, at this point, it's not a problem since the fillets need another thin coat to fill in some low spots that developed. The Microlight sands much easier than Expoxolte or epoxy & micro balloons and feathers very well.
RG [8D]
In the past I've always use SIG Epoxolite to make wing fillets. The Epoxolite is a good product but is a real bugger to sand! For this project the filler I used is [link=http://www.westsystem.com/ss/]West System[/link] #410 Microlight Fairing Filler with their #105 resin and #206 hardener. I've been wanting to try West System epoxy for several years and decided it was time. I've heard a lot of good things about their products.
The epoxy and filler were mixed as per the instructions to a peanut butter consistency and applied to the fillet area. To shape the fillet I used a vinyl decal removal tool called the [link=http://www.lidcoproducts.com/Chizzler_Squeegee.cfm]Chizzler[/link]. It has the perfect shape, and worked well. Much better than my inconsistent finger!
After the filler had cured I noticed a few air bubbles. Not sure if this is normal for this product or if I did something wrong. Most likely it was something I did!
Either way, at this point, it's not a problem since the fillets need another thin coat to fill in some low spots that developed. The Microlight sands much easier than Expoxolte or epoxy & micro balloons and feathers very well. RG [8D]
12-05-2011, 06:55 PM
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RE: My Wood & Foam Bridi UFO Build
ORIGINAL: iampilot2
R_G, Great information! Does this material sag?
I found out there is a distributor less than a mile from were I work.
R_G, Great information! Does this material sag?
I found out there is a distributor less than a mile from were I work.
It really depends on how much filler you add to the epoxy. There's no definite ratio of epoxy to filler. I think I actually mixed it a little too thin, which is why I ended up with several low spots, hence the need for a second coat. I think with more practice I'll learn how to judge the correct consistency for the job at hand. So far I think it's a good product. I really like the way it sands and feathers, about like Bondo. It would be cool to have a local supplier!
Here's a [link=http://www.westsystem.com/ss/adding-fillers/]video[/link] that demonstrates the 4 types of consistencies that West System refers to in their instructions.
Here are some more [link=http://www.westsystem.com/ss/how-to-use-demos/]demo videos[/link]. Also, a lot of very good info [link=http://www.westsystem.com/ss/use-guides/]here[/link].
RG [8D]
12-18-2011, 07:55 AM
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RE: My Wood & Foam Bridi UFO Build
The second coat of filler has been applied to the fillets and sanded smooth. I also sanded the lower rear portion of the fillets to shape. At this point, with the exception of some minor filling, the fillets are pretty much done. The West System epoxy & filler worked well and I will definitely be using it more often in the future.
The plans show a small fillet on the lower trailing edge of the wing which blends that part of the wing into the fuselage. The fillet is so small that I think I'll just leave it off all together. It's hardly noticeable, even on the plans.
Next up is the wing chin block.
RG [8D]
The plans show a small fillet on the lower trailing edge of the wing which blends that part of the wing into the fuselage. The fillet is so small that I think I'll just leave it off all together. It's hardly noticeable, even on the plans.
Next up is the wing chin block.
RG [8D]
12-24-2011, 08:18 AM
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RE: My Wood & Foam Bridi UFO Build
Thanks Brad! I think you'll like the West System filler.
Finished up the chin block this morning.
Nothing really out of the ordinary here, pretty straight forward. I did vary slightly from the plans in that I used a piece of 1/16" plywood for the front piece of the chin. The plans call for balsa. Using the thin ply as a former instead of 1/4" balsa made it a little easier to match that piece to the fuselage without having to do a lot of extra sanding on the wing side, as would have been necessary with the 1/4" balsa. The ply also makes it a little more "ding" proof!
RG [8D]
I think you'll like the West System filler.Finished up the chin block this morning.
Nothing really out of the ordinary here, pretty straight forward. I did vary slightly from the plans in that I used a piece of 1/16" plywood for the front piece of the chin. The plans call for balsa. Using the thin ply as a former instead of 1/4" balsa made it a little easier to match that piece to the fuselage without having to do a lot of extra sanding on the wing side, as would have been necessary with the 1/4" balsa. The ply also makes it a little more "ding" proof!
RG [8D]
12-24-2011, 08:25 AM
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RE: My Wood & Foam Bridi UFO Build
The block was glued to the wing using 30 minute epoxy. I added a small epoxy & micro balloon fillet around the perimeter to give it a more finished look.
I still need to fill in the small gap between the wing and saddle at the leading edge of the wing.
RG [8D]
I still need to fill in the small gap between the wing and saddle at the leading edge of the wing.
RG [8D]
12-24-2011, 01:34 PM
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RE: My Wood & Foam Bridi UFO Build
Got most of the gap filled with a couple small pieces of balsa. I'll finalize it with a little epoxy and micro balloons.
Mele Kalikimaka,
RG [8D]
Mele Kalikimaka,
RG [8D]
12-25-2011, 08:30 AM
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RE: My Wood & Foam Bridi UFO Build
This morning I finished up the gaps with some epoxy & micro balloons. This completes the wing saddle and chin block.
Looks like it's time to attach the tail feathers! This thing's going to start looking like an actual airplane pretty soon!
RG [8D]
Looks like it's time to attach the tail feathers!
This thing's going to start looking like an actual airplane pretty soon!RG [8D]
12-27-2011, 06:46 AM
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RE: My Wood & Foam Bridi UFO Build
I mean this is the nicest way...people like you really pi$$ me off[:@]
I can build straight, I can build light, and I can build strong...but I don't build all that pretty. You on the other hand do it all. I would cover my plane in clear monokote to show off the wood work!!
NICE WORK!!!!
I can build straight, I can build light, and I can build strong...but I don't build all that pretty. You on the other hand do it all. I would cover my plane in clear monokote to show off the wood work!!
NICE WORK!!!!
12-27-2011, 05:58 PM
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RE: My Wood & Foam Bridi UFO Build
ORIGINAL: JeffH
I mean this is the nicest way...people like you really pi$$ me off[:@]
I can build straight, I can build light, and I can build strong...but I don't build all that pretty. You on the other hand do it all. I would cover my plane in clear monokote to show off the wood work!!
NICE WORK!!!!
I mean this is the nicest way...people like you really pi$$ me off[:@]
I can build straight, I can build light, and I can build strong...but I don't build all that pretty. You on the other hand do it all. I would cover my plane in clear monokote to show off the wood work!!
NICE WORK!!!!
Thanks!
RG
ORIGINAL: Roary m
I take it Sig has dropped Epoxylite Putty?
I take it Sig has dropped Epoxylite Putty?
RG
12-31-2011, 10:05 AM
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RE: My Wood & Foam Bridi UFO Build
Before moving on to the tail feathers, this seemed like a good time to add a hard point for the tuned pipe mount.
I had originally planned on using a Macs Products Pipe Mounting Kit. I'm sure the Macs kit works well enough, but I didn't care for it's homely looks, so I made my own from a piece of aluminum bar stock. The only parts of the Macs kit that I used were the cradle and the little piece of foam tape. I'm guessing the tape uses a silicone based foam so it can withstand the heat.
The new Long Bend Header put the pipe further away from the fuselage than I was hoping for. When it comes time for the final assembly I might do something different to bring it in a little.
RG [8D]
I had originally planned on using a Macs Products Pipe Mounting Kit. I'm sure the Macs kit works well enough, but I didn't care for it's homely looks, so I made my own from a piece of aluminum bar stock. The only parts of the Macs kit that I used were the cradle and the little piece of foam tape. I'm guessing the tape uses a silicone based foam so it can withstand the heat.
The new Long Bend Header put the pipe further away from the fuselage than I was hoping for. When it comes time for the final assembly I might do something different to bring it in a little.
RG [8D]
12-31-2011, 10:17 AM
#545
RE: My Wood & Foam Bridi UFO Build
Ralph-
Would you be willing to make a mold for the UFO and send it to Don in CA to make canopies? Your work is impeccable. I am thinking it would be as good or better than any CNC type made mold...
It would help a lot of us... just saying.
A clear canopy would be sweet.
Brian
Would you be willing to make a mold for the UFO and send it to Don in CA to make canopies? Your work is impeccable. I am thinking it would be as good or better than any CNC type made mold...
It would help a lot of us... just saying.
A clear canopy would be sweet.
Brian
12-31-2011, 10:27 AM
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RE: My Wood & Foam Bridi UFO Build
Thanks very much Brian!
Right now I'm leaning towards a one off, glass over foam canopy. But who knows, the canopy is still 2-3 weeks away, things can change.
RG
Right now I'm leaning towards a one off, glass over foam canopy. But who knows, the canopy is still 2-3 weeks away, things can change.
RG
