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Old 05-16-2018, 02:15 PM
  #101  
RodneyFord
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Third canopy, this is the lightest and came out of the mold cleanly and easily.

Old 05-17-2018, 06:00 PM
  #102  
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Outer layer, kevlar up the front.



In the bag with 1.5mm rohacel /peelply.



Nice and cosy in electric blankets.
Old 05-19-2018, 02:34 PM
  #103  
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Here is the second side before the inner layer of 26gm glass. High vacuum forces the rohacel to fully conform to the mold.




Excess resin is forced through the perforations into the peel ply. Before inserting the rohacel into the mold I deresined the glass with a couple of applications of paper towels.
Old 05-20-2018, 12:00 PM
  #104  
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OK so I want some stiffeners down the center of the fuselage.. My plan is to glue in these 30mm wide strips of 2.75mm rohacel reinforced with carbon tissue (2 layers on each side). Here they are,30gms.

Old 05-20-2018, 02:42 PM
  #105  
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Fixture to hold position.
Old 05-20-2018, 08:35 PM
  #106  
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Got the fuselage joined, too busy and sticky to get shots.



Cut strips for joining. The glass is 2 layers of 80gm laminated with spay glue 45/90 orientation. This stops fraying and stretching.
Old 05-21-2018, 01:15 AM
  #107  
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Out of the mold very easily. Pretty happy with the weight.


Old 05-21-2018, 02:31 AM
  #108  
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The front end is 1oz kevlar over 3/4oz glass. The corners have carbon rovings and epoxy/microballoon mix in them.
Old 05-21-2018, 02:33 AM
  #109  
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Carbon reinforcement for the engine mounting plate.
Old 05-21-2018, 02:36 AM
  #110  
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The undercarriage mount has 1.5mm ply sandwiched between 100gm carbon.
Old 05-21-2018, 02:39 AM
  #111  
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Kevlar reinforcement for the tail wheel and I may put in a ballast box to tune the CG.
Old 05-21-2018, 02:44 AM
  #112  
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The seams worked out cleanly. I put in a bead of epoxy/micro balloons on each edge first. The glass strip was pre-wetted and de-resined before attaching. I used the lap joint method for assembly.
Old 05-21-2018, 02:46 AM
  #113  
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These flat sections also had a rohacel core.
Old 05-21-2018, 02:51 AM
  #114  
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Not sure where the wing tube will go. That will depend on the balance. The rear end used 75gm glass instead of my original plan to use 50gm. It is much more ding resistant and not a big weight penalty. The entire fuselage is cored with 1.5mm rohacel, it is very stiff.

Last edited by RodneyFord; 05-21-2018 at 02:55 AM.
Old 05-21-2018, 02:57 AM
  #115  
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Just needs the cross braces.
Old 05-21-2018, 04:30 AM
  #116  
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Wow Rod, that looks amazing!
Old 05-21-2018, 04:06 PM
  #117  
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With cowl and canopy.
Old 05-22-2018, 02:29 AM
  #118  
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I usually start by setting up the stabs. I set up this false tail post with access hole to hold the fuselage in position. I need to get the tail surface honey combed so Ewan can have his foam cutting guides back.

Old 05-22-2018, 02:34 AM
  #119  
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While I was cutting MDF for the false tail post I made a blank for making the 4" spinner mold.

Old 05-23-2018, 08:32 PM
  #120  
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Stab cores with tube and balsa ply supports.
Old 05-23-2018, 08:34 PM
  #121  
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Honeycomb cutting.
Old 05-23-2018, 08:35 PM
  #122  
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3.1 grams saved! Awesome.
Old 05-23-2018, 08:40 PM
  #123  
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6.6 gms saved out of the rudder. That's 12.8 gms total for the tail surfaces. Of course it is also the glue saving.
Old 05-24-2018, 08:27 PM
  #124  
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Well it is done but I think my usual system is probably just as light and a lot easier.



Ready for the balsa skin. 3K carbon tow stiffeners.




In the press.

Last edited by RodneyFord; 05-24-2018 at 11:40 PM.
Old 05-25-2018, 03:05 PM
  #125  
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71 gms so that's 15gms too much glue.

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