Tsunami - composites, part 2
 

Since the original thread http://www.rcuniverse.com/showthread...79&forumid=113 was getting too long, I'm continuing it here.

So, after a few months' hiatus, construction begins on a new Tsunami for myself and finishing my brothers. We did not get to prime his today, but I was able to wax, paint and prep the molds over the weekend. Because of today's holiday, I had the chance to layup a stab.

Our goal, as stated previously, is to fly the new composite wings on my Tsunami fuse. Hopefully, better construction and care on my part will yield lighter results this time on the hollow core wing.

Photos will come as we get time to work on the models. I anticipate updates every couple of days so you can see the progress.

Michael

Here's the stab in the mold - Note that I used red this time when painting my molds prior to layup. This way, the part will come out red, and hopefully need minimal filling before painting..

Tsunami - composites, part 2
 

Here's the fuse and wing the molds prepped for layup. Stab is in the vacuum bag. In two weeks' time, I hope to have a complete wing and fuse out of the molds and being put together. The nice part about composites is that most of the hard work is done once it comes out of the mold.

Michael

Tsunami - composites, part 2
 

Props.... hmmm, all the way from Australia you say?

15x14 at 9500 rpm?

Is that carbon fiber?

Tsunami - composites, part 2
 

14 pitch ?!$#@!^#???

Tsunami - composites, part 2
 

Looking great Michael!

Tsunami - composites, part 2
 

Hey Mike,

I just found the previous thread... and now this one. Great job!

I have a couple of questions for you regarding your home build vac. bagging system.

1) How?
2) How much?
3) Where can I get the parts to build my own?

If you have time - shoot me an e-mail ([email protected])

Thanks,
Ted
p.s.
We missed you yesterday at the field. It was not a good day... 6 went in. 4 total losses. 1 Minor repairs needed. 1 just needs a new tail wheel.

Tsunami - composites, part 2
 

5/29/02 Update:

Stab is closed up and out of the mold. No photos yet. Camera is on loan for a day or two. Next up is prepping materials for fuse and wing, along with primer on Chris's Tsunami.

Stab came out light, and strong. skin hinge should be much better than the last stab. More flexible, yet sufficiently strong.

Also, I will be putting together some info on home made vacuum baggers soon for those interested.

Michael

Tsunami - composites, part 2
 

Vacuum bagger intrest here!!!

Sweet - can't wait to see it. You can use my camera if you need to!

TRP

Yes!
 

Hi Michael,

This one's looking even better than the first! Nice work.
I love the photos. Please keep 'em coming.

Tsunami - composites, part 2
 

Forgot to pick up the camera from my brother's for photos tonight, but I did go out and cut the flashing off of the stab, cut the elevator edges, and check the skin hinges (very nice this time)! I weighed the stab and it is 4.1oz. Not bad. The heaviest part is the aluminum joiner (3/16") and all of the epoxy/milled fiber around it. I'm certainly progressing. I can't wait to do the wing this weekend!

Michael

Tsunami - composites, part 2
 

Got the camera back, so I snapped some photos

Stab out of mold with flashing trimmed

Tsunami - composites, part 2
 

Skin hinge detail

Tsunami - composites, part 2
 

Bottom of stab with hinge up. I used 1/32" balsa on this one for skins with 3/4 oz glass on the inside and 1.5 oz outside.

Tsunami - composites, part 2
 

Chris's Tsunami wing awaiting primer

Tsunami - composites, part 2
 

Chris's fuse... A little work on the fillets and she should be ready for primer.

Tsunami - composites, part 2
 

Got to the garage for a brief period this weekend.....

Here's the wing "core" template and the core sheeting layed out. I've got really nice 1/16" AAA contest balsa this time.

Tsunami - composites, part 2
 

Sheeting being test-fitted in one part of the wing mold

Square cutouts are raised areas in the mold where the aileron bays will be. This makes an indent in the wing where the servo hatch will fit. I used a piece of 1/16" abs plastic that is double face taped to the mold. Really thin, what looks like scotch tape that has adhesive on both sides is used to attach it to the mold. The strip cutout is where the bottom gets a recess too. I use layers of trim tape to build this up.

Tsunami - composites, part 2
 

All sheeting test fitted in mold. I cut most of the glass and ran out of poop for the day. Will continue tomorrow after work.

Michael

Tsunami - composites, part 2
 

Michael,

Things are looking great!

How much deflection are you using on the ailerons and flaps? Are you at all worried that the skin hinge on the flap will fatigue over time?

Thanks,

Tsunami - composites, part 2
 

The ailerons used approximately 1/4" on my balsa/foam wing. It did have gap seal, but I imagine that it will improve with a true composite wing, thus needing maybe 3/16" aileron throw.

The flaps work great on this plane to slow it down. Actually, it really didn't need them, but I liked having it. However, the wing used to be about 11% thickness and I have increased it to a little over 12% for the molded wing. This ought to reduce needed flaps a little. I am actually using the flaps for camber changing in the turns more than for landing. I don't think that I can get the 70 deg I used last time with the camber, but I'll live with 30 or 40 deg.

My elevator skin hinge came out great this time and if the wing is the same, I think it will be ok. The bottom line is that I've seen skin hinges work very well for long periods. I definitely overdid my brother's wing and I'm hoping the servos will take it. This one should be much better.

Michael

Tsunami - composites, part 2
 

Yahoo! First evening in weeks I actually got 4 hours in the garage!

Layed up my Tsunami wing tonight. First photo was taken at 8:30pm and shows the materials basically laid out.

Tsunami - composites, part 2
 

8:50 pm - Glass wetted out on top wing mold. I used two layers of 1.4oz cloth for the outer layer this time.

Tsunami - composites, part 2
 

8:58 pm - Carbon put near trailing edge of wing and first wing halve core laid down

Tsunami - composites, part 2
 

9:46pm - Both wing panels in the mold. Layup was as follows:

(Outside)
2 layers of 1.4oz
1/16" contest grade balsa
6oz Carbon near landing gear, LE, and TE areas.
Carbon tow along spar location
1.4oz glass
(Inside)

Tsunami - composites, part 2
 

10:00pm - Peel ply was added to each halve and then they were put in the bag and the vacuum pump turned on.