California Smelly...yak 2

[ARUP]

Pretty cool! Blue foam is great!

[MarnochS]

Cowl separation so I can glass it for plug purposes. The 3M 77 spray adhesive did a good job of keeping things together.



Since I'm going to need tail weight I might as well put the flight / ignition batteries in the back. Used a CamLoc fastener the make access easy.
I liked Len's cover plate for access to the tail wheel servo

[Swiss1]

Nice stuff Scott, but as you made it a turbine version, you should install a turbine!!
Who's CamLok are you using?

Jeremy
SCCAAA TT TN

[MarnochS]

Hi Jeremy,
The CamLoc thats pictured are CamLoc 4002-3 ( Cad plated , 0.111-0.141 depth ) series Studs and the Cad plated receptacles. I see on the Aircraft-Spruce website there are a couple of options now. It was a toss-up weather to go Phillips or slotted......all depends what type of hole / dent you want to put in the skin when you miss......

The turbine would be super cool but just not practical for towing and the 25 hr maintenance interval is a bit of a hindrance.

Scott

[LRFitch]

Scott, super cool! I hope this new tug gets a chance to tow my repaired KA-6 this summer. Maybe I should say, I hope my KA-6 can be towed up by your new tug this coming summer. Thanks again.
Larry

[MarnochS]

Hi Larry,
Looking forward to towing your big KA-6.

Some fun stuff today, made the little turtle deck on top of the cockpit and covered it with 1/64 ply. I used overhead projector clear sheets to copy the profile image off my computer screen after zooming in to get the approximate size.


Since the instrument panel and sheeting is a different shape than the Radial cowl, I used some paper and tape to approximate the correct shape and then "sanded to shape".



Next step is some fiberglass on the forward deck and then the Cowl

[MarnochS]

Getting closer to being a Plug.....primer....sand....primer....sand.....prim er......sand...

the white primer doesn't build up very much like the gray stuff (primer&filler) from Krylon.

.

[MarnochS]

Fun with Epoxy & fiberglass....

mocked up a parting board with some construction paper and then transferred to some 1/8" plywood. Covered it with some leftover UltraCote. Who says a parting board has to be white......
Attached with hot melt glue after waxing the ..... out of the plug.




I'm committed now..........for better or worse....I'm planning on a 3 part mold......easy part first......


Graphite powder gel coat and then glass and then mat ( the stuff that is needle like when you get some epoxy on a fiber )

[MarnochS]

So....the hot melt glue did a little damage to the plug, not much , just melted the primer......on a good note, the Frekote 700-NC is super cool as the parting board came off with out a problem.



Next step is the front parting board.....a little more challenging to construct but the construction paper made is pretty simple.



Stickers via USPS.......and more fiberglass via UPS and http://www.Thayercraft.com

[MarnochS]

Productive day on the Cowl mold
Saw a video on YouTube where they used the partall wax to seal the seams and thought I'd give that a try......It would work really good if I'd have painted my plug with a two part epoxy primer. Since it was only rattle can primer, the wax partially removed some of the primer ( food for thought next time....). Other than that, it worked great......



Then on to the other side......



Now, the real trick will be to extract the plug........

[French1]

Well Done Scott, really great work!

[MarnochS]

Successful Extraction ...YEA !!!






After some cleanup with solvent to get the primer out ....time for the Frekote Mold Sealer ( FMS ) wipe on process.

[ARUP]

Nice work with the plug and molds. Builds arm muscle, too!

[MarnochS]

Thanks Mike.

Two layers of 5.8 oz plain weave. On the intake scoop to spinner transition, it's a bit of a severe angle.....found if I cut a 1" strip at a 45 degree angel to the weave, it lays down nicely.



Reinforcing tapes and some 410 microlight fairing filler on the intake scoop.

[ARUP]

Wouldn't it be nice to have some of those fancy bladders to put in there to hold the glass in place in an assembled mold? Nice work with a tedious process!

[MarnochS]

Going with a split cowl and Ring mount so I added the divider (two layers of 1" standard fiberglass tape ( Partall Film #10 brushed on the top cowl )



and then I couldn't stand it any longer and just had to get it out of the mold.......


YEA !! !!

[gunny11]

Very interesting!