Doug,
I'd bet that you and I are in the minority. I've molded several hundred composite models and the most important things about them is they are all the same. Straight, true and light. They come out of the molds painted and none of them required any trim. other than locating the proper cg. I guess the point I'm trying to make is, no one that has no working knowledge of hollow composites should be making any kind of decisions concerning the legality of those technologies in reguards to the current BOM rule.
I'd like to read your write up for your hollow parts, I'm always looking for better ways to make parts.
Arch
Arch,
Here is my reply to Frank Williams from a few weeks ago about what goes into composite parts. If you have built 100s then you are way ahead of me I am sure. Tell me what you think.
Frank,
You are right. They are not carbon. They are glass balsa sandwich. Top and bottom halves ready to take paint. I am told they come from the mold filled. That is how I built mine. Top and bottom halves glass balsa sandwich complete span wise parts. Left me two parts to glue together. Glued them together in the cradle the foam male parts were cut from, using thin CA! Straight as an arrow! NO RIBS IN MINE!!! Weight was about 2-3 oz heavier than balsa tissue but I went straight to paint, NO FILLER!! Put that wing I made in a HUGE profile and it flew AWESOME!!
If someone were to buy those halves from me I would have been the one who did about 90% of the building. Here's how it goes.
1. I made the design, cut the male part from foam, sheeted the male part, filled the male part, primed the male part, clear coated the male part, buffed and polished the male part. The male part is finished in the same fashion as your full on stunter. It has to be as clean and smooth because it dictates the finish you will have in your female mold. That has to be perfect! That alone is a total build in itself. Then attach it to a perfectly flat strait piece of SUPER HARD wood as a base.
2. Then I pulled a female mold from the male part (there is another 8 or 10 steps in making the female mold), then prepped the mold, made a few test vacuums to get the mold ready for use. This is a huge undertaking on a wing.
3. Lets not forget the whole vacuum setup and all that is needed to actually even attempt this in the first place.
4. Then cut the glass, cut the balsa to create perfect fitting skins, and cut the next layer of glass. Set these aside for now.
5. Then wax the mold, several coats for sure.
6. Then spray release agent in the mold, then second coat, then third coat, then fourth coat, you go until it is light green and no flaws, sometimes you have to clean it all off and spray it again, yes spray it with a spray rig no brushing here. Spray at about 60-80psi.
7. Then spray in the primer coat, whatever color you like, use a weighted amount to get the weight you want within a few grams per wing half. Let this completely dry.
8. Then in goes the epoxy, spread it all around as thin as possible using a roller as not to damage the primer and more importantly the release agent below the primer. It is very lightly attached the mold and will move with the slightest pressure of a sharp edge of any kind.
9. Lay in the what is to be the outer coat of glass, the tightest weave you have, I used 2oz crows foot weave. Roll it in and let the epoxy soak in. There can be no wrinkles in the glass. It is gluing to the primer you just sprayed in. That is how it comes out ready for paint!
10. Squeeqy out all the epoxy, there should be so little left you can barely feel it. Now you can pull it down in the vacuum from here with a bleeder cloth to get out all the epoxy and then come back for a second pull with the rest or you can do it all in once. If you have you act together you can do it all in once but it can make for a heavier half if you do so. I pull it twice.
11. I then add in some carbon on the tip since it is a compound and wood wont go there. Talk about the perfect hollow tip!!
12. The mold is placed in the vacuum bag and pulled at 15 for about 30 hours. This is the first pull. I use teflon bleeder cloth placed over the glass to remove excess epoxy. If you put in the balsa skin and pull all at once I cant get out the excess epoxy from the top/first layer of glass. The balsa will absorb it and it will be heavy. I use proset super slow epoxy to give me the longest potlife when setting up the wing.
13. Remove the wing/mold 30 hours after initial vacuum. Remove teflon bleeder cloth. BE VERY CAREFUL not to move the part. Remember the release agent it is very slippery stuff and the part will come out of the mold. NOT GOOD!
14. Roll in more epoxy and place in the balsa skin.
15. Lay out your next layer of glass on wax paper and roll the epoxy there and squeegy off as much as you can. I mean the glass should feel almost no epoxy on it. But you dont want to EVER directly touch the stuff! You do this out of the mold so the balsa doesnt absorb excess epoxy. Or you could use Roecell! I have. It works killer but is brittle anyone squeezes on launch and your wing gets crushed.
16. Lay in that pre-prepped layer I used 1oz cloth here.
17. Back in the bag for 30 more hours at 15.
18. Now the excitement is building. All day at work just wanting to get home and get that part out. Remove the mold from the bag pull the bleeder cloth. Very carefully lift the part out. It will just slip right out if the release agent is properly sprayed in the mold.
20. Wash the part off with water and trim the flashing. Being extra careful not trim into the seam so it will be straight!! That is very important.
21. Then repeat the process from 4 on to get you another wing half.
From here on is where you the customer would take over the project.
22. Once you have 2 halves then you lay one halve in the foam cradle.
23. Install bell crank.
24. Install line slider, make sure it will attach to the top skin when you join them.
25. Install TW box.
26. Install wing gear blocks if you go that route.
27. Top wing half is placed on top of the bottom wing halve. Put epoxy on the top of the slider so it will attach to the top of the wing. Hobby epoxy is ok here. It should lay there with no pressure and be lined up all the way around. Having the cradle makes it a snap. A FLAT TABLE IS A MUST. You cannot do this properly without it! I build on a marble slab.
28. Use CA to attach the halves together. Glue on one end, then the other opposite, then work your way around the wing gluing it together at points not one continuous bead. Take your time. It took me well over an hour right here.
29. Once the wing is CA together all the way around with no gaps you are done.
30. Install hinges and flaps and stick it in the fuse.
31. When finishing the fuse you will cover the wing because it is fully ready for paint when you receive it.
I am fully confident the Yatsenko planes/parts, all of them, are built in a similar fashion/process. $2000-3000 bucks! Totally worth it. Take it from someone who has done it. You can also see where the greater chunk of the build is required.
I have built one and it was a total success. First try! And it was awesome. The next time I could make it way better from things I have learned during my first run and from what Windy has done with theirs and from what I have seen from the Yatsenkos. I had plans for more but it fell through as I dont have the time needed to stay after it on a project like this. But I do have all the stuff and can do it again. I do plan to one day revisit the whole thing when I can be more devoted to it.
Doug Moon