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Fouga magister 1/4.5 moulded from scratch

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dirk tinck24/05/2019 23:40:06
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211 forum posts
358 photos

So ,computer time !

With the first bottom wing mould dry ,time to clean up the edges20190519_195429.jpg

dirk tinck24/05/2019 23:41:45
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211 forum posts
358 photos

Take away the supporting board and foam blocks20190519_195609.jpg

dirk tinck24/05/2019 23:45:32
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211 forum posts
358 photos

20190519_201149.jpg20190519_195650.jpgClean up and wax.....again20190519_195643.jpg

dirk tinck24/05/2019 23:47:05
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211 forum posts
358 photos

Sealing with PVA20190519_211703.jpg

dirk tinck24/05/2019 23:59:13
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211 forum posts
358 photos

With the PVA dry,it's time for epoxy and glass : 50 gr ,100gr , 5x200gr gives a thickness of around 2mm.

The little glass cutting are added for future laminations like future layers but in this case it's to accept some reinforcements to strenghten the mould. they garanty a good adhesion.

I also placed reinforcements to the center-mould at a third and two thirds of the span .They also help to prevent the mould from warping when turned arround for laminating the actual wing...Yes were getting there !!20190519_233813.jpg

dirk tinck25/05/2019 00:00:11
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211 forum posts
358 photos

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dirk tinck25/05/2019 00:28:37
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211 forum posts
358 photos

Next step before "unwrapping" the 5 moulds, is to connect them all with bolts .Not just drill and put a bolt in ,nope !

The bolts are there to make sure that whenever the moulds are bonded,the're at the exact same position every time.

This is my system to achieve this:

Drill the holes with a 6.5mm drill.

Place a 2cm long piece of broom-stick(drilled in the center with a 6.5 mm drill ) on both sides of the composition with 30min epoxy and place a 6mm bolt in the hole.

before the epoxy is cured , remove the bolt and let dry.

When cured , drill again with a 8 mm drill. let the 6.5mm hole guide the 8 mm drill so that you have a perfect 8 mm hole.

Now fit a 8mm bolt with a UNTHREADED part in the hole and you have a perfect fit without play !

You can buy special systems for the same goal but hey,that 's money saved !!

If you neglect this,you end up with a difference in height on the centerline of the moulded parts wich you have to solve with filler and i hate that when it's possible to prevent.20190521_224547.jpg

dirk tinck25/05/2019 00:41:46
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211 forum posts
358 photos

20190523_210015.jpg20190523_205959.jpg20190523_205936.jpg20190522_225421.jpgWhen everything bolted together ....unbolt itsmile p.

Now we can carefull try to de-mould the whole system after a clean-up.

Guess what !!The wing popped out without mechanical intervention !!Me happy !!thumbs up20190522_225421.jpg

dirk tinck25/05/2019 00:53:43
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211 forum posts
358 photos

After a good clean-up of the moulds (remember water dissolves the PVA) i will clean up the flap and aileron moulds.

After that it's time for the second wingembarrassed.

The next series of foto's illustrates the de-moulding of the flaps and ailerons

dirk tinck25/05/2019 01:12:39
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211 forum posts
358 photos

20190524_223116.jpg20190524_223204(0).jpg20190524_223332.jpg20190524_223459.jpg20190524_223659.jpg20190524_223736.jpg20190524_223910.jpg20190524_224009.jpg20190524_224039.jpg20190524_224143.jpg20190524_224244.jpg20190524_224327.jpg20190524_224531.jpg

Bob Jennings 131/05/2019 10:46:50
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133 forum posts
190 photos

It's like watching a magician at work. That wing mould looks amazing.

Steve Houghton 131/05/2019 11:30:24
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1883 forum posts
128 photos

Very impressive Dirk yes

Phil Cooke02/06/2019 08:58:42
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2235 forum posts
1525 photos

Superb work Dirk! The methods and skills demonstrated in how you're ably applying them is really impressive to see explained pictorially like this - we do have some serious talent within our ranks here that's for sure! thumbs up

I'm looking forward to seeing how you join and reinforce the 2 wing halves!

dirk tinck06/06/2019 22:29:54
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211 forum posts
358 photos

Thanks Bob, Steve and Phil for the nice comments,i really needed a little boost after a windless PSS weekend in France.Driving 1600km to put a electric glider in the air isn't funny at all.

Not much new to show ,exept for the 4 flaps en ailerons being ready to take on the second half of their mould.20190605_205337.jpg

dirk tinck12/08/2019 22:59:21
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211 forum posts
358 photos

Good evening all !

It's been a long time sinds i posted something so here we go:As promissed ,the flap and ailerons-moulds are a fact now and the 2nd wing is well underway to have his own moulds,just a few nights away20190611_223650.jpg

dirk tinck12/08/2019 23:01:42
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211 forum posts
358 photos

20190612_214801.jpg20190612_214747.jpg

dirk tinck12/08/2019 23:02:56
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211 forum posts
358 photos

2nd wing20190718_012550.jpg

dirk tinck12/08/2019 23:03:31
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211 forum posts
358 photos

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dirk tinck12/08/2019 23:04:13
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211 forum posts
358 photos

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dirk tinck12/08/2019 23:05:05
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211 forum posts
358 photos

opposite side20190808_231223.jpg

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