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Fouga magister 1/4.5 moulded from scratch

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dirk tinck27/10/2018 23:45:29
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20181026_230112.jpg20181027_222359.jpg20181027_232845.jpgCutted the openings in the balsa all in one time to get two exact the same bottomside shells with reference points at the end.At the same time did the top shells but they only need the opening for the air brakes.For clean edges i used the dremel and a metal ruler20181027_232853.jpg

dirk tinck28/10/2018 00:11:46
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184 forum posts
323 photos

Before glueing the balsa to the cores,I'm going to add a layer of glass cloth and epoxy to the foam where the openings in the balsa shells supposed to come , this gives me the bottom of the openings later. Pic. for example. Remember this is all done to mould the wings !! I hope you guy's can follow !! It will all be clearer later20181009_195633.jpg

dirk tinck04/11/2018 18:44:59
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184 forum posts
323 photos

With the wing cores ready,glassed where the openings in the balsa will come,the only thing left to do is to sand the inside of the shells where they meet at the trailing edge.With a metal ruler beside the balsa i can keep the minimum thickness of 1mm at the edge.20181102_223013.jpg

dirk tinck04/11/2018 19:03:03
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184 forum posts
323 photos

Glueing both upper and bottom shell in one time means everything needs to be ready and in place :30min epoxy will set in not much less time !

Apply the glue to both shells , positioning them on the core ,get the supporting foam parts in place and press the whole down on a flat board.I added all the weight i could find.

Not much later the epoxy started curing...Time for a drink !!smile p20181103_224105.jpg

dirk tinck04/11/2018 19:10:36
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184 forum posts
323 photos

20181104_131245.jpg20181104_131228.jpgAn important step behind me :2 perfect balsa covered foam cores with the openings for retracts,servos airbrakes already in place.

Very happy with the leading-and trailing edges perfect straight ,washout mesured,and the suface itself !!!20181104_131211.jpg

dirk tinck04/11/2018 19:23:21
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184 forum posts
323 photos

Hi all !! Need some help on thisone !

Any body here with expereance in wing tube-diameters ? I want to use the smallest possible because it 's going right trough the air duct !

there's room in the wing for dia 30mm going 35cm far in the wing

or dia 35mm going 30cm far in the wing (each side)

Any idea's ? Alu ? carbon ? Wall thickness ?

McG 696904/11/2018 19:23:53
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2475 forum posts
976 photos

Splendid and very neat job, Dirk.

As you wrote yourself, I don't suppose your progress and goals are very 'clear' if somebody never worked with or making moulds for composite parts. surprise

I guess it will become more obvious to visitors when you have your moulds ready to be waxed, gel coated and so on.

Keep up the great work. yes

BTW, I didn't notice any 'glass' for that intended celebration... not very 'Belgian' like... angel smile p

Cheers

Chris

dirk tinck04/11/2018 21:20:33
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184 forum posts
323 photos

Hi,Chris

I'm well awere of the fact that moulding parts can be complicated for unexperianced visitors but i'm trying to keep it as simple as possible.embarrassed

The forms you want to make in polyester or ,in this case epoxy,have to be made first in any material you choose to work with,possible cheap and strong enough so it dusn't deform when handling.Every scratch,line,bump or dent will be there in the moulded part.In fact , this is the easy part crook

And no , i'm not a BEER Belgianangel

cheers ,Dirkcocktail

sean burchfield08/11/2018 09:08:02
2 forum posts

Ive been watching your work with great interest. A fabulous aircraft to model and clearly a real craftsman at work. Not many of you left now it seems.

dirk tinck17/11/2018 21:21:33
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184 forum posts
323 photos

Evening all !

I was a few days off the map but here we go again anding the leading edges20181105_223938.jpg

dirk tinck17/11/2018 21:33:23
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184 forum posts
323 photos

20181107_224014.jpg20181107_211211.jpgGlueing a balsa list to the wings ,all with epoxy. I could do this with foam for easy sanding and then covering with balsa but that would take much more time and i have some scrap left so...

sanding the real leading edges after shaping them with a new blade was easy with the soft balsa.20181107_200737.jpg

dirk tinck17/11/2018 21:57:30
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184 forum posts
323 photos

time to ''drill'' the wing tube holes ...I did a few tests in some scrap foam and what really works best is a sharpened tube with a slightly smaller diameter.

So the wing tube is 30 mm (i hope thats enough) and goes 30 cm deep in the wing half. I found a piece of tube of 28.8 mm (ex party tent) to drill the holes. Not the easyest task as this will provide

1 : a straight wing , what we want

2 : a wing with some dihedral ,what we don't want( pos. or neg.)

The fact that the cutting tube is 1.2mm smaller than the hole i want,gives me the chance to correct it a little bit with sand paper wrapped arround the tube.(after the hole is drilled)

While ''drilling)by hand , the cutting tube is supported by 2 foam blocks glued to the flat board,paralell to the trailing edge and perfect in line with the middle of the wing root. The distance to the leading edge is chosen according to the form of the landing gear opening and preferable in the thickest part of the wing.20181111_150759.jpg

dirk tinck17/11/2018 21:58:45
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184 forum posts
323 photos

Tha went really well !! No correction needed.20181111_150822.jpg

dirk tinck17/11/2018 22:00:14
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184 forum posts
323 photos

The same MO fot the wing tiptank tubes20181114_223301.jpg

dirk tinck17/11/2018 22:14:11
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184 forum posts
323 photos

Time to form the wing tips

This is not an ordinairy wing tip as the round tiptank would leave a gap between tank and wing

To get the perfect shape i glued some scrap balsa to the wing,roughly shaped it and then added some filler.While drying i pushed the tank into the filler and left to dry.For easy loosening i left a thin layer of plastic on the filler.The tank was held horizontal with a foam block.

Bang !No sanding needed !!

BTW the tiptank is one i made fot the PSS version wich was to heavy.20181115_223611.jpg

dirk tinck17/11/2018 22:26:35
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184 forum posts
323 photos

The only thing to do before separating the ailerons and flaps is to close the wing at the root with balsa.

Everyting square,horizontal ,epoxy please !The first wing is already drying standing up and pressed against the sealing.After the epoxy has set,made the tubeholes in the balsa,carefully not disturbing the foam.

Time to do a test : Put a peace of tube in both the wings and inspect the leading edge.

Straight or not ,let's see tomorrow

20181116_234333.jpg

dirk tinck17/11/2018 22:29:04
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184 forum posts
323 photos

Nonono !Can't wait ! Have to see the result noyes????

dirk tinck17/11/2018 23:07:59
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184 forum posts
323 photos

20181117_235206.jpg20181117_235220.jpg20181117_235251.jpg20181117_235201.jpgHappy with the result !cheekyNow , clean up that mess before you go-on !!!!20181117_234009.jpg

dirk tinck17/11/2018 23:12:44
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184 forum posts
323 photos

The center section of the wing is 100% straight ,however the outer sections ,starting at the ailerons,have some dihedral because of the washout.

Tomorrow we have a swap-meet at a local club so no progress tomorrow

Greets, Dirk

Ben Van Raemdonck19/11/2018 18:28:53
2 forum posts
7 photos

wing internal 2.jpgWell the internal structure of the Wings are comming together as well.

wing internal 1.jpg

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