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Old 06-18-2013, 06:56 AM
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Stabs and vertical fin are cut and here are the turttle decks being cut. Now its time to start sheeting all the foam!!
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Old 06-18-2013, 07:14 AM
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Approaching critical AoA...
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United States, VA, Fredericksburg
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Hi Al,

Thanks for all the pics - interesting to see all the work going into making just the kit.

Just curious - what density foam do you use? Also, what happens to all the excess foam: does the manufacturer recycle it or do you just chuck it?

Pete
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Old 06-18-2013, 07:47 AM
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Hi Pete,

How are things in France? We currently are using virgin 0.85 lb EPS foam which I get locally. Actually funny you ask about the scrap pieces.

We do not recyle back to the supplier but very little gets thrown away. We use some for packing material and I give some to my landloard who does the same. Then one of my guys takes some and gives it to a friend that make different things out of it. Jerry takes a few pieces and makes a pilot out of it. So in a way it gets recycled. Why you need some!! LOL

Al
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Old 06-20-2013, 06:58 AM
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Haven't been able to get much done on planes this week. One of our key employees was in a serious car acident last weekend and got banged up pretty good. He is going to be ok, He recieved a pretty good gash from eye level to the top of his skull. He managed to get a helicopter ride out of it!! Thank God nothing more serious. Hopefully he will be out of the hospital tomorrow and recoop at home for a bit. He has been with me going on 15yrs!! So with that I have been filling he's job as well as my normal day activities.

Just glad he's ok!! We will try to get started on sheeting some foam this weekend!!

Al
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Old 06-23-2013, 04:17 PM
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RC 'Aholic!
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Hey Al
Just a suggestion, how about a 120 " wingspan/ 110 or so length fuse extra 300? Huge elevators/ ailerons
You can call it the
Radio wave 3D !
You know for us 3D guys;-)
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Old 06-23-2013, 05:01 PM
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Quote:
Originally Posted by RollingHarrier View Post
Hey Al
Just a suggestion, how about a 120 " wingspan/ 110 or so length fuse extra 300? Huge elevators/ ailerons
You can call it the
Radio wave 3D !
You know for us 3D guys;-)
OK

when do you want it?
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Old 06-24-2013, 07:06 PM
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Got a chance to get some work done on both planes. Kevin and I edged all the sheeting for both planes. We plan on using gorilla glue for sheeting all the surfaces so we are actually using packaging tape to hold the sheeting together. If there are any gaps in the sheeting the gorilla glue will fill the voids. Easier to do then gluing the edges and much easier to sand when done.

We will lay carbon toe down to give the wings good strength between the foam and sheeting.

Picture to come
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Old 06-24-2013, 08:08 PM
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Each stab half on our 3.1 is 22 inches long. Here I have cut 24" lengths and taped them together. The forth picture shows the stab shuck which is used for our template to cut the sheeting to size.
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Old 06-25-2013, 01:49 PM
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So with things starting to get back to normal here we had a chance to start vacuum bagging the foam parts. First we are doing the turtledecks. As like the pictures above for the stabs all we do is cut the balsa pieces to length and tape them together. Again, the gorilla glue will fill in any voids in between sheets. Then lay the balsa sheeting into the shuck and you can trim it up to the correct size.
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Old 06-25-2013, 02:03 PM
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After getting the sheeting ready we are now ready to vacuum bag the turtledecks. We recommend putting some newspapers down on your building table and then laying your turtledeck sheeting on that. Take a squirt bottle with water in it and mist the balsa sheeting. Then take the gorilla glue and spread it across all the sheeting with a squeegee. Lay the sheeting in the outer portion of the shuck and then insert the turtle deck and inner shuck to help hold shape.

We use the vacuum system from aerospace composites at about 5-6 HG which works out great. While we use a vacuum system for convenience and to help speed up the process a bit you can certainly do all the sheeting of the foam parts with just weighing down the shucks to hold them into position.
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Last edited by jtec/radiowave; 06-25-2013 at 03:27 PM.
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Old 06-26-2013, 10:27 AM
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Here are the finished turtledecks. With the temperatures being so high and a fair amount of humidity the cure time was really quick yesterday. We were able to pull the turtledecks out in about an hour and a half and they were completely set.

Here are a couple of pics
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Old 06-26-2013, 11:45 AM
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Since we are done with the turtledecks we have moved onto the rudders. Since the cure times are so quick with the gorilla glue we have decided to do one rudder at a time so we do not rush anything and make a mistake. The steps for rudder sheeting is exactly the same as turtledecks.

Our vacuum pump is setup to do two bags at once so if we have time we may try and get both bags going at the same time.

Here is one of the rudders in the vacuum bagging process.
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Old 06-27-2013, 12:07 PM
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Continuing right along we just put the second set of stabs in the vacuum bag. Here are some pictures from a couple of minutes ago of us prepping the stabs.
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Old 06-27-2013, 12:38 PM
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Do you warm the Gorilla Glue to thin it like Krazy Kark does or do you use it at ambient temp?
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Old 06-27-2013, 12:40 PM
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Do you have to use a new bag after each run or are the bags reusable?
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