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Fouga magister 1/4.5 moulded from scratch

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Phil Cooke17/08/2019 08:27:27
2381 forum posts
1637 photos

superb work Dirk - great to see all the mould components laid out like that - a fantastic achievement - a labour of love!

McG 696917/08/2019 10:24:25
2894 forum posts
1097 photos

... great to see all those parts finally together in one picture. yes

Not long to go now before getting the 'reward' of your first mould end pieces, Dirk.

As we say in Belgium: "Nen dikke proficiat, man". wink



Martyn K17/08/2019 19:43:42
5041 forum posts
3677 photos


How does the cost stack up for a scratch built model like this.

It really is glorious


dirk tinck18/08/2019 23:36:04
446 forum posts
704 photos

Hi Chris, Thanks !

Hi Martyn, That's a damn good question !

I cant tell you exactly but halfway the build (airframe) i made a rough estimate and i must have spend around 1500 €. (I hope my wife dusn't read this).

The fuselage is going to cost a lot less,because i can use the moulds of my PSS model.

The real cost is going to be the motor ,esc,landing gear and electronics.

Let's hope i can sell a few kits,and get some money back .cheeky

dirk tinck02/10/2019 23:23:58
446 forum posts
704 photos

Hello guy's ,Long time no see ! But here i am again.

As much as i want to make some wings in the new moulds,for the moment it's not yet possible .There is still doubt about the sandwich material (airex,cork or some other thin foam sort).

Second issue is my vacuumpump wich is still not ready for duty...

So the wings have to wait a while.

Dusn't mean i'm gonna watch TV at night...

Got the fuse moulds out,waxed them ,covered them with PVA.

Next thing is to both laminate them with 50gr,100gr,and 3 layers 200gr.

No gel coat or in mould coating ,as the result is going to serve as the new plug for the edf fuse.

There's more than 1 reason why this fuse is not going to be used to fly

1st: To make the construction as simple as possible,the wings are ''flat'' on the root-side.This makes it necessary to put the profile of the wing onto the fuse.

2nd I need a hatch for the motor

3rd I need a gear door opening

4th To simplefy the construction of the rudders,thesame solution is needed (like the wings)

But most of all , The exhaust openings are too small for edf.They were scale on the PSS version (62mm) and i need 72mm for edf. This problem was solved by placing a dummy in the moulds.The form won't be perfect but easy to correct after.

So let's make a fuse !!

dirk tinck02/10/2019 23:52:18
446 forum posts
704 photos

20190420_225036.jpgthese are the exhaust dummy's.It's easyer to do this now than to20190420_225030.jpg cut away a piece after moulding

dirk tinck02/10/2019 23:55:55
446 forum posts
704 photos

First half :20190912_224940.jpg

dirk tinck02/10/2019 23:59:27
446 forum posts
704 photos


dirk tinck03/10/2019 00:01:11
446 forum posts
704 photos

20190915_215510.jpgedges cleaned up20190915_215336.jpg

dirk tinck03/10/2019 00:02:50
446 forum posts
704 photos

other side20190918_223633.jpg

dirk tinck03/10/2019 00:09:10
446 forum posts
704 photos

After cleaning up the edges it's time to bolt them together.Before that i'm making up some glass bands 6-7cm wide to laminate over the seam on the inside.

This is not a easy task(my arms are not long enough !!)20190919_213258.jpg

dirk tinck03/10/2019 00:18:23
446 forum posts
704 photos


dirk tinck03/10/2019 00:22:48
446 forum posts
704 photos

after drying ,time to un-mould.By forcing some wooden wedges between the mould halves,and twisting them there should be bo problem taking them apart.Here the PVA has to to his job together with the wax.20190921_230936.jpg

dirk tinck03/10/2019 00:25:52
446 forum posts
704 photos


dirk tinck03/10/2019 00:28:21
446 forum posts
704 photos

Another milestone in the fouga history !No defaults ,no airbubbles,exhaust adaptation perfect !

dirk tinck03/10/2019 00:39:30
446 forum posts
704 photos

Next day's (evenings)will be spend on adapting the wings on the fuse,placing the wing tube and anti-rotating dowels.

All this has to be done,keeping in mind the 2 deg. wing incedence (pos). After the wing profile is set onto the fuse , it will be too late to change this.Every fuse coming out of these moulds will have the same incedence angle !!

Stay tuned !!

Chris Freeman 303/10/2019 05:04:41
315 forum posts
445 photos

That is a work of art! Very nice. I admire the work that you are doing. I have done a few fiberglass fuselarges and each time I do one I get more appreciation for work like you have done as I always need to fill areas that should have been better.

Stephen Jones04/10/2019 18:29:40
2762 forum posts
1598 photos

Fantastic work ,

Looks great so far, All that hard work seems to of paid of.


Mark Elen04/10/2019 18:43:38
401 forum posts
738 photos

Some people take our hobby to another level. You, Sir, are one of those.

Beautiful work.



john s04/10/2019 18:59:59
63 forum posts
2 photos

Been following this thread from the beginning and find it absolutely fascinating, the quality of your work is outstanding.


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