Thanks Ricardo. Marking and cutting the canopy and cowl splitter plates.

https://cimg7.ibsrv.net/gimg/www.rcu...31139bc795.jpg
https://cimg4.ibsrv.net/gimg/www.rcu...dba22f4d3f.jpg

Unfortunately I have gotten complacent with my LiPo's and had one flame last night. Fortunately the only damage was to the plug the battery the charger and my feelings. It will take a wee while to repair this but the upside is I will remodel the upper intake as I think I can make it look better.

https://cimg4.ibsrv.net/gimg/www.rcu...e8d62ba68c.jpg

Sorry for the danage, fortunatly nobody was hurt. Keep the hard work. Next time it will be better.

Yikes! That really stinks... ;-( How close was the fuselage to the battery pack? How hot did the battery get? I'm sticking with glow power!!!!

Repair nearly done. Have been thinking about schemes, probably a lightening bolt theme.

https://cimg1.ibsrv.net/gimg/www.rcu...80660a37e3.jpg
https://cimg2.ibsrv.net/gimg/www.rcu...75d61f6dcf.jpg

Got the new upper nose air intake on, Also took the opportunity to do a bit more surfacing on the canopy and cowl.

https://cimg8.ibsrv.net/gimg/www.rcu...700a18d10a.jpg

Hi Rodney,
It is looking really good. Great color scheme! You mentioned that you were planning to power the Zeus with a DA 55. That is a lot of weight in the nose. How are accommodating the large amount of nose weight in the design? A few here in the USA have moved the wing forward. I am thinking of trying a pumped Moki 210, myself. Also a lot of nose weight plus a header and a pipe.
Thanks,
Will

Yes Will I will be installing a DA50. I might mill the head like my 200 which will remove 100gms. My plan is to build it without installing the wing tube so I know where the CG will be. I will install the wing last. The servos will be at the front too. The idea is to be able to move the wing as far forwards as possible for the longest possible tail moment. I'm going to do a custom header and cannister.

https://cimg1.ibsrv.net/gimg/www.rcu...b5a21cbf43.jpg

I have a good supply of Hemi Orange in the paint store. I put plenty on so I can sand it flat. I wouldn't say the surface was super stable, maybe a few more layers of glass would have helped. As long as I don't put it in the sun it is OK though.

https://cimg9.ibsrv.net/gimg/www.rcu...d92c3960cc.jpg

https://cimg3.ibsrv.net/gimg/www.rcu...1d4ce4575f.jpg

https://cimg6.ibsrv.net/gimg/www.rcu...f795706225.jpg

https://cimg2.ibsrv.net/gimg/www.rcu...132fc30aaf.jpg
https://cimg1.ibsrv.net/gimg/www.rcu...51a26b3314.jpg

Shot a guide coat and sanded it out with 800 wet.

https://cimg3.ibsrv.net/gimg/www.rcu...a4bdc23935.jpg

Machine polished it plus a bit of elbow grease. This is ready for molding.

Great

https://cimg6.ibsrv.net/gimg/www.rcu...a88b50689b.jpg
https://cimg7.ibsrv.net/gimg/www.rcu...03bace6439.jpg

Cowl and canopy also ready for molding. It will take a couple of days to set them up in the splitter plates.

https://cimg6.ibsrv.net/gimg/www.rcu...bff6cec123.jpg
https://cimg7.ibsrv.net/gimg/www.rcu...76acf6833e.jpg
https://cimg8.ibsrv.net/gimg/www.rcu...8bc70b7ace.jpg

A few last pics before molding.

Looking good Rod, nice looking machine 😁

https://cimg1.ibsrv.net/gimg/www.rcu...d3d1d75823.jpg

In between coats of release on the plug I am making brass inserts for the stainless mold registration pins. I need 40 of these.

Looking slicker than greased snot on a door handle. 40 registration pins??? Seems like a lot! But I guess to many is better than to few.

Ken

Hi Ken its really 20 pins and 20 sockets per mold half. Three molds so it adds up.

https://cimg1.ibsrv.net/gimg/www.rcu...a2b1d06114.jpg
https://cimg2.ibsrv.net/gimg/www.rcu...28b0b7a3e3.jpg

Setting up the splitter plates for molding.

Looks good.👍👍

https://cimg7.ibsrv.net/gimg/www.rcu...aa5d1fbdc6.jpg

To seal the splitter plates I use modelling clay. Also some tools.

https://cimg6.ibsrv.net/gimg/www.rcu...cffae9fe1e.jpg

Roll worms and press them into the gap. I have chamfered the splitter plate so the clay doesn't fall through.

https://cimg8.ibsrv.net/gimg/www.rcu...df8d726933.jpg

This is the main tool to form the seal.

https://cimg9.ibsrv.net/gimg/www.rcu...3ca4088d99.jpg

https://cimg0.ibsrv.net/gimg/www.rcu...d34636ae25.jpg

The release agent also cleans up the clay nicely.

https://cimg1.ibsrv.net/gimg/www.rcu...965bd0dcb3.jpg

https://cimg2.ibsrv.net/gimg/www.rcu...d0bec7af72.jpg

Finished.

Greeting Rod, Just found this thread after a long talk with Hamish today. Brilliant work as usual, needless to say I'm subscribed, thanks for sharing. Looks like the perfect home for a DLE 55RA. Hope to see you in the Bay 21 & 22.
All the best, Barrie.

https://cimg6.ibsrv.net/gimg/www.rcu...3fe3736d39.jpg
Hi Barrie, hopefully will make it on the 22nd. The DLE rear exhaust seems like a good option and it is if you are using a commercial can. However if the can is right up behind the motor the side exhaust header can enter the side of the can. Off course this requires a custom header and can. Need to see how it works out in practice but building one should be easier than 2x ZDZ 120 pipes I did for the Jungmann .

https://cimg7.ibsrv.net/gimg/www.rcu...f66e616862.jpg

Got the dams and alignment sockets done.

https://cimg0.ibsrv.net/gimg/www.rcu...f4b4aafec1.jpg

Filled the screw heads with clay so they don't fill with resin.

https://cimg1.ibsrv.net/gimg/www.rcu...0ab1e953d3.jpg

I will probably leave the dams on the molds for soft edges.

https://cimg2.ibsrv.net/gimg/www.rcu...33ee20842b.jpg

Made a vortex mixer for the gel coats.

Lots of work to this point. Looking good! Is the mold epoxy or polyester resin?

Ken