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Author Topic: REvolutions  (Read 6236 times)

Offline TDM

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Re: REvolutions
« Reply #50 on: November 21, 2017, 02:27:00 PM »
Today's work
Is a pain in the ass when the ATC is not working. Ideally you want to set the machine and go home. When you return next day the part is done.
Each goal you meet is a moment of happiness
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Offline jfv

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Re: REvolutions
« Reply #51 on: November 21, 2017, 03:58:33 PM »
Very nice.  I'm very jealous.
Jim Vigani

Offline TDM

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Re: REvolutions
« Reply #52 on: November 22, 2017, 05:51:43 PM »
The evil twin has arrived  VD~

The aluminium plates are used to hold the nose section and the back section together in perfect alignment so I can sand in assembly. That way when I assemble the nose section to the rear section the parting line will be perfect or so I am dreaming of.
Each goal you meet is a moment of happiness
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Online Avaiojet

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Re: REvolutions
« Reply #53 on: November 22, 2017, 07:29:42 PM »
Traian,

Absolutely outstanding!  H^^

I've never seen this kind of workmanship in this Forum before?

There's also balloon bladders that are placed inside the mold and the material. When inflated they push the material against the mold. I believe some parts are made this way, wings for an example.

Or am I thinking of something else?

Great work!

Charles

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"No one has ever made a difference by being like everyone else."

Marcus Cordeiro, The "Mark of Excellence," you will not be forgotten.

I look at the Forum as a place to contribute and make friends, some view it as a Realm where they could be King.

"Ya gotta love it when a plane comes together."

Proverb 11.9  "With his mouth the Godless destroys his neighbor..."

"Perhaps the greatest challenge in modeling is to build a competitive control line stunter that looks like a real airplane." David McCellan, 1980.

Offline TDM

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Re: REvolutions
« Reply #54 on: November 23, 2017, 06:37:53 AM »
Charles that is called “inflation bladder molding” it is good for parts that are fabric only like a only carbon fuselage (when you lay the material it stays on the mold walls without pulling off the mold) and for that you need a rigid mold because it has to take the pressure without distorting. I will use this technique in making the wheel pants for this bird. Ant that is the only place I will use this technique. And baloons are bad for bladders because the epoxy eats then they burst and make a mess. I had many of them burst and destroy hundreds of dollars 💵 worth of material.

Happy thanksgiving to everyone thanks for watching I hope we all learn something new and make better stuff all the time. Also thanks for all your impute and friendship.

Traian
Each goal you meet is a moment of happiness
Happiness is the harmony between what you think and what you do. Mahatma Gandhi

Offline TDM

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Re: REvolutions
« Reply #55 on: November 28, 2017, 02:30:38 PM »
Since the machine is not behaving I am using the time polishing the fuselage molds. The part I do not like about this material is that is hard to see what is done or not done. As soon as it is wet (wet sanding) you do not see anything in there. You have to sand blind, and you have to dry it out and see the results from sanding.
But if that is the worst I am taking.
Each goal you meet is a moment of happiness
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Offline TDM

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Re: REvolutions
« Reply #56 on: November 29, 2017, 08:41:08 PM »
Results from the last few days of polishing
Each goal you meet is a moment of happiness
Happiness is the harmony between what you think and what you do. Mahatma Gandhi

Online Crist Rigotti

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Re: REvolutions
« Reply #57 on: November 30, 2017, 11:31:40 AM »
Nice!
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Offline TDM

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Re: REvolutions
« Reply #58 on: December 27, 2017, 09:15:49 AM »
Wing molds are done ✅
Working on polishing those things
The flaps are built in the molds so there will be one step layout for the wing mold followed by the joining plus a little hardware inserts
Each goal you meet is a moment of happiness
Happiness is the harmony between what you think and what you do. Mahatma Gandhi

Offline David_Stack

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Re: REvolutions
« Reply #59 on: December 27, 2017, 11:18:01 AM »
Impressive work Traian!

Do you intend to use kevlar or comparable to hinge the flaps as an integral part of the layup?  Any concerns that the hinges will be too stiff if so?

r/
Dave

Offline TDM

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Re: REvolutions
« Reply #60 on: December 29, 2017, 06:48:43 PM »
Dave i can go either way with plastic hinges or Kevlar. If i go Kevlar then i will use a light Kevlar 1.7oz one layer of it for hinges. I left some 1/32 flat gap at the hinge which should give a nice flexible hinge. There are other alternatives of using several short hinges instead of a continuous one. Nylon cloth is also an option this will all be decided as the project evolves.
Thanks Traian
Each goal you meet is a moment of happiness
Happiness is the harmony between what you think and what you do. Mahatma Gandhi

Offline TDM

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Re: REvolutions
« Reply #61 on: December 31, 2017, 06:55:27 PM »
 I have got off my lazy butt and I managed to finish polishing the wing molds.
 Enjoy the pictures.

 By the way happy New Year’s guys.
Each goal you meet is a moment of happiness
Happiness is the harmony between what you think and what you do. Mahatma Gandhi

Online Avaiojet

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Re: REvolutions
« Reply #62 on: January 01, 2018, 07:07:49 AM »
I have got off my lazy butt and I managed to finish polishing the wing molds.
 Enjoy the pictures.

 By the way happy New Year’s guys.

Traian,

BAM! You certainly have that airfoil down, locked and loaded!

You did mention an era for composites and a new look at building construction and materials for electric. Interesting your project being started just in time to celebrate 2018 with just that happening with the REvolution!

Well named also, a 'revolution' that model is!

Charles

 
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"No one has ever made a difference by being like everyone else."

Marcus Cordeiro, The "Mark of Excellence," you will not be forgotten.

I look at the Forum as a place to contribute and make friends, some view it as a Realm where they could be King.

"Ya gotta love it when a plane comes together."

Proverb 11.9  "With his mouth the Godless destroys his neighbor..."

"Perhaps the greatest challenge in modeling is to build a competitive control line stunter that looks like a real airplane." David McCellan, 1980.

Offline TDM

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Re: REvolutions
« Reply #63 on: January 11, 2018, 11:45:39 AM »
I am getting almost every day material in for this. Some from oversea some local.
I was playing with battery compartment and this is what I came up with. It can be configured for any TP battery pack whether it is a 3S up to 6S and i f i go with anything under 6S i can adjust it up and down in 5/16 increments. Each rail (gray color) is held in place with one screw.
« Last Edit: February 20, 2018, 02:11:37 PM by Traian Dorin Morosanu »
Each goal you meet is a moment of happiness
Happiness is the harmony between what you think and what you do. Mahatma Gandhi

Offline TDM

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Re: REvolutions
« Reply #64 on: January 14, 2018, 06:53:16 PM »
On my to do list is
Face plates (end plates for the molds) For the fuselage (2) one for the wing mold and one for the horizontal stab mold
Templates to cut components.
I will need templates for foam for carbon. That means templates to cut big parts and also I will means templates to cut several patches and small stuff. Each part gets several templates made.
Hardware
Take apart hardware control system hardware motor mount hardware battery compartment formers maybe landing gear stuff.
Paint templates most of the templates are vinyl cut but some are not.
I need to make special formers root ribs and hard points. these will be 1/6 balsa with 90g carbon on both sides.
I need to make sanding jigs for the fuselage inserts and cut the foam that will plug those areas.
Right now I have all the material on hand.

Some initial decisions for layout solutions (which i call best guesses) came after getting advice from may in the composite world specialists and some of the CL molders that dared to endeavor in this direction.
Fuselage will be 200g/M2 one layer with one layer of .75oz fiberglass cloth. and some reinforcements here and there. In the deep cavities there will be Divinycell machined to correct shape and 90g carbon on the outside. In the nose area i can go with perhaps 2 layers one 200g one 90g or the 90 will be patches here and there
Horizontal will be CW30 on the outside 1mm foam and .75 fiberglass on the inside. for spar I am usisng unidirectional 100g/m2 the hinge will be Kevlar
The wing will be same as the horizontal except the foam is 1.5mm.
So there is where I am heading.
Each goal you meet is a moment of happiness
Happiness is the harmony between what you think and what you do. Mahatma Gandhi

Online Avaiojet

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Re: REvolutions
« Reply #65 on: January 14, 2018, 07:38:26 PM »
Traian,

Ohhhhhhhhhhh My Gosh!

Hey! Do you have any idea how inadequate you make me feel? I can't be the only one?   n~

Where did you learn all these techniques? This can't be your first attempt?

Traian,

You should get the "Builder of the Year" award for 2018.

 H^^

Charles
Please visit my updated Website! www.cfcgraphics.com

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Alpha Mike Foxtrot.

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"No one has ever made a difference by being like everyone else."

Marcus Cordeiro, The "Mark of Excellence," you will not be forgotten.

I look at the Forum as a place to contribute and make friends, some view it as a Realm where they could be King.

"Ya gotta love it when a plane comes together."

Proverb 11.9  "With his mouth the Godless destroys his neighbor..."

"Perhaps the greatest challenge in modeling is to build a competitive control line stunter that looks like a real airplane." David McCellan, 1980.

Offline TDM

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Re: REvolutions
« Reply #66 on: January 15, 2018, 06:59:38 AM »
Charles I have spent some 5 years plus in the glider community building DLG and learning a whole bunch about the composite construction techniques and have spent hundreds of hours just researching. I have learned about just every molding techniques there are possible and practiced them all too. In the process i made a CNC machine from scratch learned to do hot wire cutting and also made my own gravity hot wire cutter i learned about vacuum bagging regular molding techniques then about inflation bladder about layouts then moved to CNC molds (I do this for a job as I am a machinist) once i graduated to CNC molds then it open the door to do hollow molded components then the solid core components was next also a one piece fuselage was in the works too so I have learned to make that too. It was quite a journey a exiting journey full of disappointments and success.
Each goal you meet is a moment of happiness
Happiness is the harmony between what you think and what you do. Mahatma Gandhi

Online Avaiojet

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Re: REvolutions
« Reply #67 on: January 15, 2018, 07:32:21 AM »
Charles I have spent some 5 years plus in the glider community building DLG and learning a whole bunch about the composite construction techniques and have spent hundreds of hours just researching. I have learned about just every molding techniques there are possible and practiced them all too. In the process i made a CNC machine from scratch learned to do hot wire cutting and also made my own gravity hot wire cutter i learned about vacuum bagging regular molding techniques then about inflation bladder about layouts then moved to CNC molds (I do this for a job as I am a machinist) once i graduated to CNC molds then it open the door to do hollow molded components then the solid core components was next also a one piece fuselage was in the works too so I have learned to make that too. It was quite a journey a exiting journey full of disappointments and success.

Traian,

I kinda figured you had some background or experience with these kinds of materials. What you are doing doesn't happen over night.  H^^

Certainly puts the old school method of wrapping balsa skins around a foam mold or using planking around a crutch.

Guys like me certainly can appreciate your abilities and your 2018 contemporary approach to modeling.

Your better than me.

Better than anything I've seen actually. This means your efforts give guys like me ambition.

However, even with the ambition, what you are doing is far beyond the reach of most modelers. My 'reach' isn't long enough.  LL~ 

I used planking strips on Pushy Galore. It tired me out.  n~  Some guys are still doing sheeting over foam. It works for us old school guys.

I'm thinking, with all that engineering, math and tooling, you could go into production. I mentioned I have someone interested in your design AND would consider a model.

Are product sales in store for the future?

Good for you!

Charles
Please visit my updated Website! www.cfcgraphics.com

If you're Trolled, you know you're doing something right.

Alpha Mike Foxtrot.

Owner of CFC Graphics. "Model Airplane Graphics from a Model Airplane Builder."

"No one has ever made a difference by being like everyone else."

Marcus Cordeiro, The "Mark of Excellence," you will not be forgotten.

I look at the Forum as a place to contribute and make friends, some view it as a Realm where they could be King.

"Ya gotta love it when a plane comes together."

Proverb 11.9  "With his mouth the Godless destroys his neighbor..."

"Perhaps the greatest challenge in modeling is to build a competitive control line stunter that looks like a real airplane." David McCellan, 1980.

Offline TDM

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Re: REvolutions
« Reply #68 on: January 15, 2018, 11:59:33 AM »
Right now I am not sure about sales. Mainly because I don't have time to do this.
Speaking of Pushy i think you took the hard way approach to it. It is relatively easy to make a buck out of a few formers put foam between them and make a plug suitable to mold cigar-ish shaped objects. For mold you can do it with two layers of balsa wood cling wrap Elmers glue and Ace band aids. That is easy to do. after you mold you lay it flat and the you walk a Exacto knife blade around the parting line.
Each goal you meet is a moment of happiness
Happiness is the harmony between what you think and what you do. Mahatma Gandhi

Online Avaiojet

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Re: REvolutions
« Reply #69 on: January 15, 2018, 12:25:03 PM »
Right now I am not sure about sales. Mainly because I don't have time to do this.
Speaking of Pushy i think you took the hard way approach to it. It is relatively easy to make a buck out of a few formers put foam between them and make a plug suitable to mold cigar-ish shaped objects. For mold you can do it with two layers of balsa wood cling wrap Elmers glue and Ace band aids. That is easy to do. after you mold you lay it flat and the you walk a Exacto knife blade around the parting line.

Traian,

I'm well aware of the method of which you describe. I made a choice and decided to build from the inside out, as I generally do.

I'd have to do my homework but I'll take a guess, I believe Lockheed, in their early days, the 20's possibly, built aircraft just about the same way. They pressed plywood together in large molds under tons of pressure to make fuselages.

I like planking because I've built many models this way. I have plenty of planking left over from many Berkeley kits. I'm kidding.

I may remove the wings on Pushy Galore and use what's left as a tether car.

Charles
Please visit my updated Website! www.cfcgraphics.com

If you're Trolled, you know you're doing something right.

Alpha Mike Foxtrot.

Owner of CFC Graphics. "Model Airplane Graphics from a Model Airplane Builder."

"No one has ever made a difference by being like everyone else."

Marcus Cordeiro, The "Mark of Excellence," you will not be forgotten.

I look at the Forum as a place to contribute and make friends, some view it as a Realm where they could be King.

"Ya gotta love it when a plane comes together."

Proverb 11.9  "With his mouth the Godless destroys his neighbor..."

"Perhaps the greatest challenge in modeling is to build a competitive control line stunter that looks like a real airplane." David McCellan, 1980.

Offline TDM

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Re: REvolutions
« Reply #70 on: January 18, 2018, 12:25:44 PM »
Started to work on hardware. This piece will be glued directly in the mold when i close the two halves. There is a 4250 in the picture but the AXI F2B will bolt right in. The motor mount closes the airflow to the outside on the motor. All airflow will travel through the core of the motor. It is not clear in the picture but on the outside of the mount there is a rough surface to get a good glue joint.
Enjoy
« Last Edit: February 20, 2018, 02:11:54 PM by Traian Dorin Morosanu »
Each goal you meet is a moment of happiness
Happiness is the harmony between what you think and what you do. Mahatma Gandhi

Offline TDM

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Re: REvolutions
« Reply #71 on: January 26, 2018, 09:17:39 AM »
I have most of the stuff in.
I am consulting with a firm on their release systems to make sure I give myself the best chases of success. Research and advice are priceless.
My initial goal is to make a model. I don't care too much about weight. What i want to do is learn as much as possible out of the first try. Things to learn are layout strength, planing and reality are two different things so that is another thing to consider, check templates and fine tune them this si something you almost always need to do, then I need to check strength of finished parts and also i need to check the oportunity to finish said parts after the molding process.
I have a lot more to do yet.
1: I need blocks cut for sanding the fuselage inserts. If you look at pictures you can see the fillets and root rib built in the fuselage mold.  one way that is done is to put fiber in the cavity then plug the cavity with a piece of foam cut to the exact shape (this foam has two roles: first to push the fabric against the mold wall and second is a filler creating a smooth inner surface that is much easier to mold) then lay the continuous fuselage side layer of fabric
2: I need more templates for doublers
3: Hinge material (Kevlar with resin in it)
4: root ribs and fuselage former material ( carbon balsa carbon)
5: Mold for the battery rails and cut plates to insert in the rails.
6: make hardware (I will leave this for later towards the end)
7: bill of materials for what goes in each part
8: sheer web wing spar material (glass Rohacell glass)
Starting this coming week I am doing some little molding stuff to test some of the resale systems i have on hand and I can make the ribs and former materials as i don't need release materials for that.
I might fly this bad boy by the end of February who knows.
Each goal you meet is a moment of happiness
Happiness is the harmony between what you think and what you do. Mahatma Gandhi

Offline TDM

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Re: REvolutions
« Reply #72 on: February 15, 2018, 07:08:50 AM »
I have worked on the mold end plate
This is a critical item for the take apart system. All parts coming out of the mold must be the same so they can be interchangeable, therefore the location of the spar pocket and alining pins and the control horn pocket must be the same from part to part.
Other functions for this plate is to make a perfectly perpendicular wall it needs to hold the root rib in position it creates a litle step for clearance so the elevator doesn’t rub against the fuselage and also it will make the control horn pocket.
This plate comes in place after the skins are molded as a secondary operation.
« Last Edit: February 15, 2018, 01:38:02 PM by Traian Dorin Morosanu »
Each goal you meet is a moment of happiness
Happiness is the harmony between what you think and what you do. Mahatma Gandhi

Offline jfv

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Re: REvolutions
« Reply #73 on: February 16, 2018, 08:52:59 AM »
I have to say, this is fun to watch!
Jim Vigani

Offline TDM

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Re: REvolutions
« Reply #74 on: February 26, 2018, 10:28:47 AM »
I have finished the last Mold component. The Wing root plate which works identical to the stab root plate only it is simpler in construction.
The focus this week is to fianlize the plate, fit the threded inserts in the mold, and apply release system. If I have time and the wether cooperates I will do hte first painting. The paint will be something simple an all white with some color on it. I have made stencils but I want to save them for #2.
My goals for initial build are to check fit, check templates, test the paints I have on hand I am very curious about color selection, in general prove the build sequence I envisioned when I started. There are a few things unanticipated that will go wrong, and i hope they will not be something major but as with all the new stuff things can and will happen. Nobody is perfect. If this week proceeds as planned then next week i am mixing epoxy and I start the actual build. All I have done so far was preparation towards this moment.
I have hinge material done. Maybe I can squeze in the balsa carbon sandwitch plates.
Each goal you meet is a moment of happiness
Happiness is the harmony between what you think and what you do. Mahatma Gandhi

Online Avaiojet

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Re: REvolutions
« Reply #75 on: February 27, 2018, 08:11:04 AM »
Traian,

I can't wait!

I'm sure there are many others like myself who are looking forward to the actual build.

Kudos!
Please visit my updated Website! www.cfcgraphics.com

If you're Trolled, you know you're doing something right.

Alpha Mike Foxtrot.

Owner of CFC Graphics. "Model Airplane Graphics from a Model Airplane Builder."

"No one has ever made a difference by being like everyone else."

Marcus Cordeiro, The "Mark of Excellence," you will not be forgotten.

I look at the Forum as a place to contribute and make friends, some view it as a Realm where they could be King.

"Ya gotta love it when a plane comes together."

Proverb 11.9  "With his mouth the Godless destroys his neighbor..."

"Perhaps the greatest challenge in modeling is to build a competitive control line stunter that looks like a real airplane." David McCellan, 1980.

Offline TDM

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Re: REvolutions
« Reply #76 on: February 27, 2018, 10:45:42 AM »
My moto is something every day. Yesterday I finished instaling all the brass threaded inserts in all molds that needed them.  I discovered that the pins I have in the base plates are stiking out too much. No big deal all I need to do is to press them deeper to the new level.
Relase system application is starting today.
Each goal you meet is a moment of happiness
Happiness is the harmony between what you think and what you do. Mahatma Gandhi

Offline Motorman

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Re: REvolutions
« Reply #77 on: February 27, 2018, 07:13:12 PM »
What do you use? Carnauba wax and PVA works for me.
There will be a sunny day and we will fly our airplanes.

Offline TDM

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Re: REvolutions
« Reply #78 on: February 27, 2018, 07:52:59 PM »
Chemlease Flex Z #2 semipermanent release. It is a system that has a cleaner a sealer and a final coat. Flex Z has numbers from 1-6 1 is on the sticky side 6 is like oil. 1-3 are paintable and release well. What is cool is that if the release is too slippery drop down to a lower number and try again.

PVA works too if you don’t want to paint or you just want to do any painting that doesn’t require any masking.
I want to paint in the mold the when I release the part i am done. Maybe more clear but that is it.
I was thinking of PVA for first parts but then there would be something missing fron the whole equation.
Each goal you meet is a moment of happiness
Happiness is the harmony between what you think and what you do. Mahatma Gandhi

Offline TDM

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Re: REvolutions
« Reply #79 on: March 08, 2018, 06:38:26 AM »
I mixed up epoxy yesterday and laid the Carbon Balsa Carbon stock material.
Basically is molding but there is no mold, because the piece is flat. I basically pushed the layers against a flat board of 1/4 G10 board 2x3ft in size. The idea is if you tape a piece of plastic over the G10 and you can think of it as a bag with one hard side. If you remove the air from inside whatever is in the bag will be pushed against the flat hard piece of G10 (in this case) and you get a flat component. At least on one side.

So the part is Carbon 93g/M2 plain weave 0-90 orientation, 1/16 Balsa, and same Carbon again.

On top and bottom of the part I used a flat sheet of .006 mil polyethylene (polybag) material (from McMaster Carr), this is so the part will not get glued to the flat board and it also serves as a medium for a mold surface.

The last layer on top and bottom of the poly bag material was one layer of paper towels which serve as bleeder cloths for the air to travel out of the bag.

As technique used: I got the carbon wet with a small roller on one side, then I flipped it over and made ensure the resin did penetrate and the fibers are saturated. Then I laid the carbon piece between paper towels and with a hard roller i pressed hard on the carbon so the excess resin will be soaked out by the paper towels. After that I got the piece of polyethylene and got it stuck (kind of) to the carbon. I did the same thing for the other piece of carbon.

Then I added the balsa (made sure I got the dust off the balsa) and created the part sandwitch (poly, carbon, balsa, carbon, poly). This is now ready to be vacuumed.

I put paper towels on the G10 then the sandwitch them paper towel on top of sandwitch (these towel are there only to facilitate the air to exit the bag. Then one last layer of polybag taped to the G10 (this layer is to create the vacuum bag) applied vacuum and done.
Each goal you meet is a moment of happiness
Happiness is the harmony between what you think and what you do. Mahatma Gandhi

Offline TDM

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Re: REvolutions
« Reply #80 on: March 09, 2018, 09:14:06 AM »
I feel like a freaking TV.

Here you go. I don't care about finish on these parts. What I care is that they are flat stiff and light. They will ultimately end up inside the fuselage at the root of the wing or root of the horizontal in other words you will not see them.   
Each goal you meet is a moment of happiness
Happiness is the harmony between what you think and what you do. Mahatma Gandhi

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Re: REvolutions
« Reply #81 on: March 13, 2018, 07:36:57 AM »
For those of you who care TV speaking here again.
I am switching strategy here. I am shelving the idea of CNC cutting the ribs and laminating the ribs with carbon. I will use that material for something maybe a super light ship in the future. But the hustle of laminating Carbon over balsa then cut on the machine programming etc was a bad idea (mostly time consuming).

What will I change to:
In the nose F1 F2 F3 where F2 F3 are the mating formers between the fuselage nose and the fuselage body will me 1/32 G10. That will provide a bulletproof long lasting mating surface, a rigid nose,  and a reliable and strong battery support (most my ribs are .2 wide anywise so there is not much weight there to be worried about in the first place). The rest will be 1/8 balsa wood medium strength. I will also use the 1/8 balsa for the wing and stab ribs and the aft formers in the fuselage.
That will more than enough for what I need and the weight penalty is perhaps 10grams or so.
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Happiness is the harmony between what you think and what you do. Mahatma Gandhi

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Re: REvolutions
« Reply #82 on: March 19, 2018, 06:26:07 AM »
First part is in the bag. I started with the horizontal.
In the beginning the things go a Little slower that normal. so After about two hours worth of work I got the stuff in the molds. Of course the future will me much easier because much of things I had going wrong will not. But overall no big issues at all. I think I could use a better Vacuum pressure but that i snothing to worry about and perhaps add Phelps cloth to the bag to facilitate the air travel. Like I said just some details that are a little off.
Today when I get home I will join the two halves.
Each goal you meet is a moment of happiness
Happiness is the harmony between what you think and what you do. Mahatma Gandhi

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Re: REvolutions
« Reply #83 on: March 19, 2018, 06:27:23 AM »
Picture size does not allow for more pictures in a post.

Some things I will not do again like cut the foam then apply the glass layer and cut again. I did that because I wanted to check the size of the foam piece which I know is correct now so next time I will apply the glass to the foam sheet then cut the foam and glass at same time. That should take 5 min for a horizontal set. Also I am making a list of all parts that need cutting. I should be able to cut it all in 20 min or so max. I am thinking that I can do a wing and a stab panel molding in 2-3 hours easy. I predict that i can do all prep and paint in first day. then the second day I mold everything, the third day I join everything forth day demolded and paint the wing and stab molds, fifth day mold the second wing and stab sixth day join second wing and stab and seventh day and forth assembly work. Yup in two weeks you are flying assuming that is all you do and you have the time off no kids competing for your time wife kicking your ass to weed the garden etc. All the price in time is paid upfront, in making molds templates components etc. 
Tonight I am joining the two halves and here I have a new set of parameters to adjust to. This is getting exciting now.
« Last Edit: March 19, 2018, 06:55:41 AM by TDM »
Each goal you meet is a moment of happiness
Happiness is the harmony between what you think and what you do. Mahatma Gandhi

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Re: REvolutions
« Reply #84 on: March 20, 2018, 06:00:22 AM »
OK gang.  S?P Last night I joined the two halves. Learned a few things and overall things went smoothly. I will adjust the Foam templates here and there so I don't have to do some things. I have to check fit on the sheer spar and perhaps adjust amount of splurge I put in or maybe put a much tinnier bead on both sides. And make sure i have a paper clip ready for use next time around. Also i want to do something a tiny bit different on the hinge area next time around. By the looks of it the vacuum was OK.
These are minor things and first parts are always test parts where you prove techniques and try learn maximum. The second time around you nearly cut the time in half during the process.

Also I prepared the stencils for the fuselage last night and will put them on tonight. Maybe I get to do some painting tonight. Cant wit to see how this first part turned out. I bet a little heavier than the next part but I will take a 30g part and consider it a success. That is, a 30g for a finished painted with hinge installed ready to assemble part.

Later
« Last Edit: March 20, 2018, 06:19:50 AM by TDM »
Each goal you meet is a moment of happiness
Happiness is the harmony between what you think and what you do. Mahatma Gandhi

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Re: REvolutions
« Reply #85 on: March 20, 2018, 10:19:03 AM »
Ohhhhhhhhhh my gosh!!  H^^ H^^

Outstanding workmanship.

Could well be the construction methods of future for full blown stunt ships?

CB
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Re: REvolutions
« Reply #86 on: March 20, 2018, 07:53:32 PM »
For part is out of the mold and it weighs 38g. The release was not perfect and some paint remained in the mold.
The hinge is great and smooth and it would be ready to be installed in the model. Not bad for first try. Will treat the mold with number 3 next time to get an easier release.
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Re: REvolutions
« Reply #87 on: March 21, 2018, 09:26:22 AM »
And here is the picture.
The release system has shelf life and it was old that is why I had little issues so take with salt shaker of salt what you see. 38g with hinge and hardpoint attachments.
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Re: REvolutions
« Reply #88 on: March 21, 2018, 11:24:04 AM »
That's nice, do you have to sand or polish it at all.
There will be a sunny day and we will fly our airplanes.

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Re: REvolutions
« Reply #89 on: March 21, 2018, 12:54:10 PM »
I am guessing that you refer to the paint left behind in the mold. It came out relatively easy with the help of a Popsicle stick and a damp paper towel (acetone).
I will re-polish the mold and reapply the stuff. This time I am using fresh stuff. I have fresh #1 and #3.
I put another picture so you can get an idea of the finish possible with this method. I did clear all areas that did not receive paint.
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Re: REvolutions
« Reply #90 on: March 22, 2018, 09:06:32 AM »
I repolished the mold it took about 30 min to do. After that I started the relese application. Tonight I am puting the #3 release stuff on the horizontal then I am adjusting the templates.
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Re: REvolutions
« Reply #91 on: March 22, 2018, 07:33:49 PM »
I am guessing that you refer to the paint left behind in the mold. It came out relatively easy with the help of a Popsicle stick and a damp paper towel (acetone).
I will re-polish the mold and reapply the stuff. This time I am using fresh stuff. I have fresh #1 and #3.
I put another picture so you can get an idea of the finish possible with this method. I did clear all areas that did not receive paint.

Ohhhhhhhhhh My Gosh!!  H^^
Please visit my updated Website! www.cfcgraphics.com

If you're Trolled, you know you're doing something right.

Alpha Mike Foxtrot.

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"No one has ever made a difference by being like everyone else."

Marcus Cordeiro, The "Mark of Excellence," you will not be forgotten.

I look at the Forum as a place to contribute and make friends, some view it as a Realm where they could be King.

"Ya gotta love it when a plane comes together."

Proverb 11.9  "With his mouth the Godless destroys his neighbor..."

"Perhaps the greatest challenge in modeling is to build a competitive control line stunter that looks like a real airplane." David McCellan, 1980.

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Re: REvolutions
« Reply #92 on: March 26, 2018, 08:14:41 AM »
I used the #3 Chemtrend FlexZ-3 and i had good success with it. I tested to see how is the paint laying down in the mold and when I pulled the paint out of the mold it came out without fussing.  #^ It confirmed that the expiration date of the product was the cause to all this mess.
I am waiting on some new stencils and after that I am ready to cook  S?P a new part.

I was pondering on the fuselage layout for a while now. There will be a layer of 200g/m2 which should be enough, but because it is so course and it leaves gaps between the material weaves i expect a crappy finish. So I either leave the layout a little wet, and use Epoxy to fill and bridge the gaps, or go to plan B which is to add a layer of glass on the outside with a much finer weave. I am going to plan B. so I will have a layer of fiberglass on the outside then the carbon as a inner layer. What I think is that insted of adding heavy epoxy to fill gaps (this epoxy doesn't add any strength) better to add glass and evacuate epoxy from the mold in a dry layout with higher strength and break even weight wise (rob Peter to pay Paul).  Yes I will do  little test to prove this idea. The test will be: plain carbon, .75oz glass with carbon, 1.6oz glass with carbon. May the best win.
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Re: REvolutions
« Reply #93 on: March 28, 2018, 11:15:58 AM »
I am learning at every step. when I painted the background the paint bounces and goes everywhere and them some. I was trying to use a cardboard flat on top of the mold and the paint was going mostly where i wanted it to go but some bounced and create a little haze of color in the mold like a fog. So now I am rethinking the masking for that step.
I got new stencils on hand too.

If I have time tonight I will mold the second stab. This will very likely be the last test mold I do for the wings or stabs.
By the way the Release in the Red tooling board molds works great too.
I will try to make open the schedule Saturday or Sunday to mold a bunch of stuff. 
Each goal you meet is a moment of happiness
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Re: REvolutions
« Reply #94 on: March 30, 2018, 06:24:29 AM »
Not all things are created equal. This cliche is holding true here too. The release number 3 works great on aluminum molds but if you use same thing in the Red tooling board after you paint and the paint is dry you can literay push the paint around. the roller picked the paint up off the mold. I will go to number 1 release to to get the paint to stick just a touch better.

A new horizontal is in the mold with a new layout in it and updated foam cores, you can see the cutouts that are already in the foam. I got rid of the uni in the TE that does nothing, I used the new vacuum bags which work much better than the last, I also evacuated a whole lot more resin this time around so Expecting a near perfect part.

I had some adventures in painting this part and found out that after I do stripes and switch to the fading mask free painting I need better way to do that other than a flat piece of cardboard laid on top of the mold.

I made a test to see what kind of finish do I get with .75 glass or 1.6 glass as an outer layer in the fuselage mold.

Lastly I cut the first plugs for the fuselage mold. these will go in the elevator area.
Each goal you meet is a moment of happiness
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Re: REvolutions
« Reply #95 on: April 03, 2018, 06:22:35 AM »
I had to make some decisions lately.
After the test in the tooling board material I got hit by the fact that the paint is messing up the mold finish. So I can't paint in the molds made of tooling board.
Since the only mold I have made of aluminum is the horizontal stab mold it is not worth doing the painting in the mold for just one part. Long story shot I am molding with no paint and will figure out the paint part after that. On the plus side is that I gain a couple of days of work where I have to wait for the paint to cure overnight.
Today I prep the first wing to go in the mold. I closed the horizontal mold yesterday and I am puling out the part today. I might lay another horizontal today if I have time to spare after prepping the wing materials.


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Re: REvolutions
« Reply #96 on: April 03, 2018, 05:52:12 PM »
Usable part nice finish 31.2g after I removed the flashing.
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Re: REvolutions
« Reply #97 on: April 07, 2018, 06:56:32 AM »
First wing is in the mold.
There is always a first and that is used mostly to prove disprove find problems troubleshoot etc.
I already see a couple of places where i need to trim the foam sheet template. Also I need to have a faster way to get things in the mold. It took an hour and 45min to get the two halves in the mod and I need to drop it down to about 1hour total or a little over.

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Re: REvolutions
« Reply #98 on: April 07, 2018, 07:05:03 AM »
First wing is in the mold.
There is always a first and that is used mostly to prove disprove find problems troubleshoot etc.
I already see a couple of places where i need to trim the foam sheet template. Also I need to have a faster way to get things in the mold. It took an hour and 45min to get the two halves in the mod and I need to drop it down to about 1hour total or a little over.

Traian,

That's one half of a wing vacuum bagged, correct?

I've seen vacuum bagged stuff before, that's really clean work.

I can't wait until this model is completed.

What are you going to do with all the unused trial and error parts?  #^

Charles
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Alpha Mike Foxtrot.

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"No one has ever made a difference by being like everyone else."

Marcus Cordeiro, The "Mark of Excellence," you will not be forgotten.

I look at the Forum as a place to contribute and make friends, some view it as a Realm where they could be King.

"Ya gotta love it when a plane comes together."

Proverb 11.9  "With his mouth the Godless destroys his neighbor..."

"Perhaps the greatest challenge in modeling is to build a competitive control line stunter that looks like a real airplane." David McCellan, 1980.

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Re: REvolutions
« Reply #99 on: April 07, 2018, 08:37:59 AM »
Charles thanks for the encouragement. There are both halves molded one is laying on the floor. I will try to speed things up next time around to get each mold loaded in 30 min. The trial parts I keep for testing. The usable parts will go in the first prototype. The first wing should be usable and if anything it can be the outboard wing if I feel is a little on heavy side.
I am thinking to lasercut the sheer web for next wing.
Each goal you meet is a moment of happiness
Happiness is the harmony between what you think and what you do. Mahatma Gandhi