Author Topic: BUILDING CS22 COMPOSITE BALSA SHELL FUSE (Read 7129 times)

jose modesto · « **on:** May 24, 2013, 04:24:52 PM »

I have received inquiries on how i built the CS22 fuse for the plug in models.
the fuse is constructed of 1/32" contest balsa with glass cloth and 5.4oz/sy carbon fiber cloth as a doubler
1) glue two pieces of 1/32"x4x48" contest balsa sand seams flat, wet and mold over male Buck (fuse)
The rest of process see photos
photo #1 Mold,formed balsa wood and Vac Bag
#2 epoxy and filler
#3 first layer cloth

Jose Modesto

jose modesto · « **Reply #1 on:** May 24, 2013, 04:31:43 PM »

#4 CFC interior doubler 5.4 oz/sy used for this fuse. Typically i use 2.4oz/sy CFC NOTE:since i have built numerous electric models using this fuse construction and always requiring nose weight i used the heavier cloth from CG forward.
#5 CFC Triple as this will have forward motor mount. (Hunt Mount)
#6 Wax paper to protect the bag. this allows for multiple bag use,
Jose Modesto

jose modesto · « **Reply #2 on:** May 24, 2013, 04:41:17 PM »

photos

jose modesto · « **Reply #3 on:** May 24, 2013, 04:44:59 PM »

added photos

jose modesto · « **Reply #4 on:** May 24, 2013, 04:46:40 PM »

added photos

jose modesto · « **Reply #5 on:** May 24, 2013, 04:47:55 PM »

Added photos

jose modesto · « **Reply #6 on:** May 24, 2013, 05:25:16 PM »

photo of completed CS22 is my modified SV22

MarcusCordeiro · « **Reply #7 on:** May 24, 2013, 05:47:19 PM »

Awesome!!

Marcus

James Mills · « **Reply #8 on:** May 24, 2013, 05:55:58 PM »

Thanks for posting this Jose, very cool.

James

Randy Powell · « **Reply #9 on:** May 24, 2013, 09:00:29 PM »

That's really neat. Light and structurally sound. I like it.

Matt Colan · « **Reply #10 on:** May 25, 2013, 12:35:59 PM »

Looks wonderful Jose!

jose modesto · « **Reply #11 on:** May 26, 2013, 10:59:25 AM »

Thanks guys for the kind words.
The CS22 fuse can be used to build multiple models.Since the fuse is hollow at this stage you can draw on fuse side the model of your choice. SV22,Impact, Trivial pursuit,Pattern Master ETC.
Photo sequence
The given horizontal line is the line through wing,since the fuse started life as a SV22 the motor thrust line is 3/4" above wing. Note if you are building this model as an Impact lower wing centerline 1/8" for a 7/8" wing bellow motor thrust line.
The CS22 fuse shown is being built for an electric model. the fuse can also be used to build a gas model.
Jose Modesto

jose modesto · « **Reply #12 on:** May 26, 2013, 11:01:11 AM »

added photos

jose modesto · « **Reply #13 on:** May 26, 2013, 11:10:43 AM »

PHOTOS gas fuse.
gas fuse 8oz. electric fuse 6.5 oz

RC Storick · « **Reply #14 on:** May 26, 2013, 02:14:24 PM »

Those look really good Jose!

Randy Powell · « **Reply #15 on:** May 26, 2013, 03:02:05 PM »

Jose,

So, you make the plugs with formers and foam then glass, right? Then you make the mold. So, do you vacuum bag or do you use the plug in a compression mold?

jose modesto · « **Reply #16 on:** May 26, 2013, 05:10:10 PM »

Randy the former and foam is only for the oval fuse. The Impact,SV and Saturn plugs and molds for fuse were made from individual male plug(fuse) the fuse has a parting line that runs the lengh of the fuse.
first and second photos show 2 different methods for creating the parting line
Third photo is the removal of famale mold from the male plug(fuse)
see photos
jose

jose modesto · « **Reply #17 on:** May 26, 2013, 05:14:33 PM »

Added photos
#1 female mold and male plug(fuse) for the paul ealker Impact
#2 female mold in the cofin ready for plaster emclosure
#3 mold in plater with SV fuse female mold ready for the same
Jose

Doug Moon · « **Reply #18 on:** May 27, 2013, 10:33:02 AM »

Jose,

What plaster are you using? I tried using plaster on one i made years ago and as it dried it shrunk and cracked and wasnt usable? Have you run into that problem?

jose modesto · « **Reply #19 on:** May 27, 2013, 04:43:23 PM »

Doug. The plaster is plaster of Paris the trick is to use one or two layers burlap cloth as a binder for the plaster.
I put a layer of plaster+1/2" then burlap, add plaster to complete the mold.
Note: the plaster is used to hold the female mold.
Jose

David_Stack · « **Reply #20 on:** May 29, 2013, 10:44:21 AM »

Good Afternoon Jose;

Impressive work! I don't see any sign of a 'joggle' to establish a flange, are you using seaming tape to join the two halves at the parting line?

r/
Dave

jose modesto · « **Reply #21 on:** June 11, 2013, 06:12:10 AM »

up date on CS22 fuse
The new fuse is to be used on a set of built up wing and foam tail from a previous model.
The original model was built as one of two models for the 2012 Nats. this model had suicidal tendencies.
The model posted crashed with out leaving the paved circle. the lines got caught on the concrete, model turned into the circle and proceeded
to tear the nose off.
repaired the model, second incidence the model strapped into rear seat, seat belt attached. a set of construction plans fell beside the front seat and activated the front seat to decline back. You know what happens next,seat crushes the fuse at same location of repair.
repaired model again.
photo of original model attached
second photo Batt hatch
Jose Modesto

jose modesto · « **Reply #22 on:** June 11, 2013, 06:14:29 AM »

add photos
Evil model being deconstructed
Carbon rods through fuse, these are used to allign and support Batt trey

jose modesto · « **Reply #23 on:** June 11, 2013, 06:17:58 AM »

add photos
Batt Hatch with magnets

jose modesto · « **Reply #24 on:** June 11, 2013, 06:19:58 AM »

add photos
Impact Fuse with Batt hatch and magnets
new model fuse wing and tail
new fin Note:designed and shaped by Jim Damarell

MarcusCordeiro · « **Reply #25 on:** June 11, 2013, 07:25:59 AM »

I really like this thread.
Thanks Jose...

Marcus

Derek Barry · « **Reply #26 on:** June 11, 2013, 08:23:50 AM »

Very nice work Jose! I want to talk to you at the Nats about some carbon molding. I want to learn how to make gear, wheel pants, spinners, and maybe props one day. Cant buy them anywhere anymore.

Derek

jose modesto · « **Reply #27 on:** June 11, 2013, 10:13:49 AM »

Thanks Marcus. Derek we will talk at NATS
Assembling model into one piece today.
Jose

jose modesto · « **Reply #28 on:** June 11, 2013, 10:34:37 PM »

Model in one piece
photo 1fuse and wing resting in jig
#2 gluing lower fuse
#3 first test fit

jose modesto · « **Reply #29 on:** June 11, 2013, 10:36:04 PM »

add photos
#1 rough cut balsa stab doubler waiting to sand and mate to stab
#2 model in one piece fin resting on fuse. i may extend fuse with 1/2" balsa at fuse tail post
#3 mode lin one piece front view

jose modesto · « **Reply #30 on:** June 11, 2013, 10:41:33 PM »

add photos
#2 front end you can see carbon fiber rods used to align batt trey.

Derek Barry · « **Reply #31 on:** June 12, 2013, 04:50:36 AM »

Quote from: jose modesto on May 24, 2013, 05:25:16 PM

photo of completed CS22 is my modified SV22

This plane looks awesome Jose. Look at all those ink lines...

Derek

jose modesto · « **Reply #32 on:** June 12, 2013, 05:03:22 AM »

Ink inspired by Gene Martine. A little excessive.It all started with trying to conceal the batt hatch with the inklines at fuse top.
Ink applied with 2 size sharpi markers. Dint want to clean radiograph pens. (lazy)

Thanks Derek
Jose

RandySmith · « **Reply #33 on:** June 13, 2013, 08:37:23 AM »

Quote from: jose modesto on June 12, 2013, 05:03:22 AM

Ink inspired by Gene Martine. A little excessive.It all started with trying to conceal the batt hatch with the inklines at fuse top.
Ink applied with 2 size sharpi markers. Dint want to clean radiograph pens. (lazy)

Thanks Derek
Jose

If you need to clean dried out Rapidograph pens and do not want to work, just put the tips into a bowl of Simple Green, full strength, it will work fast, and better than anything you have seen.

Randy

RandySmith · « **Reply #34 on:** June 13, 2013, 07:52:18 PM »

Quote from: Derek Barry on June 11, 2013, 08:23:50 AM

Very nice work Jose! I want to talk to you at the Nats about some carbon molding. I want to learn how to make gear, wheel pants, spinners, and maybe props one day. Cant buy them anywhere anymore.

Derek

Hi Derek

I can teach you how to make CF Props, Pants, Spinners and other items, CF gear is still available and will be for a long time to come, other items like props are dissapearing.

Randy

Steve Helmick · « **Reply #35 on:** June 13, 2013, 08:52:14 PM »

Regarding plaster, when I worked at Boeing's Mock-up FG shop in '65, we used some plaster, but mostly as a finish layer over "HydroCal". The HydroCal was often reinforced with horsehair or "excelshire" (wood fiber strands). I think the reason we used it was strength and reduced shrinkage problems. I am not at all sure that any of this stuff would still be available, but it worked well and we did make some nice parts.

Steve

Derek Barry · « **Reply #36 on:** June 14, 2013, 06:34:31 AM »

Quote from: RandySmith on June 13, 2013, 07:52:18 PM

Hi Derek

I can teach you how to make CF Props, Pants, Spinners and other items, CF gear is still available and will be for a long time to come, other items like props are dissapearing.

Randy

I know Randy and I plan on working with you on this stuff too. It is something that interests me very much.

Thanks
Derek

jose modesto · « **Reply #37 on:** August 05, 2013, 07:13:14 PM »

Airplane current status.
paint job not completed. This was one of the model being built for the Nat's
Model weight as shown 58oz real good flyer with killer corner. The small flaps and relatively low weight helps in the tigh corners.
Jose Modesto

jose modesto · « **Reply #38 on:** August 05, 2013, 07:14:44 PM »

Add photos