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Full scale engine cowling

Discussion in '* Scratch Built Section *' started by Helno, Oct 21, 2011.

  1. Helno

    Helno Member

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    My uncle makes fiberglass parts for a living and decided to to try out my phlatprinter on a project he was working on.

    We carved the mold plug in sections out of 1.5" blue foam.

    The heavily profiled sections had G-code generated with Meshcam and the lightly profiled parts were done with the phlatscript.

    It was quite the learning experience as we were limited to .5" deep cuts and initially had issues with backlash compensation but in the end had a good final product.

    It was all cut with a 1/8" 3" long 2 flute ball mill. It took a lot of machine time to make these parts. After every few parts we went around and tightened every bolt on the machine and checked the belt tension.





















    Final delivery to the customer.
    Attached files [​IMG] [​IMG] [​IMG] [​IMG] [​IMG] [​IMG] [​IMG] [​IMG] [​IMG] [​IMG] [​IMG]
     
  2. rcav8r

    rcav8r Moderator Staff Member

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    That is really cool... What did you cover the foam with to make the molds?

    And that's a rather small full scale cowling... or a large R/C cowling :D
     
  3. Helno

    Helno Member

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    He coats the foam plug with drywall mud to keep the polyester resin from eating the foam.

    That cowl is deisgned for a plane with a VW engine with the cylinders sticking out the side like a cub.
     
  4. 3DMON

    3DMON Moderator Staff Member

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    Very nice work! Neil Blanchard needs to see this as it might help him to see the light at the end of the tunnel for his car he's making.
     
  5. kram242

    kram242 Administrator Staff Member

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    This is an AWESOME project Helno! Great job too everyone involved :doubleup:
    Can that mold be reused?
     
  6. Helno

    Helno Member

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    Thats the idea. This mold is for a production kit aircraft.
     
  7. dewsy

    dewsy New Member

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    Can the mould be reused?
    Not sure the question.
    The foam was covered in the end with an epoxy to produce a plug that is the the shape of the end part. The coating provides a hard polishable surface and protects foam from resin used to make mould.
    The plug is then used to make a mould that will produce many parts.

    Cheers
    Glen
     
  8. NeilBlanchard

    NeilBlanchard Member

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    Cool -- I like how you used the 3D cutting on the end pieces where it is more important. That is food for thought.
     
  9. Helno

    Helno Member

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    The other thing Glen is planning for next time is to use thick foam for the less tapered parts and any 3d carved parts will be made in .5" foam so that they can be cut in a single pass.
     
  10. dewsy

    dewsy New Member

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    The next project is under way. Still small as was pointed out but more complex.
    This one is intended to house a Genoa engine. Just over 200cc.
    Nice to start with smaller projects when trying something new.
    Largest items being made cover Continental engines in a 2 seat side by each aircraft and the smallest is a NACA inlet duct.

    Cheers
    Glen Attached files [​IMG]
     
  11. kram242

    kram242 Administrator Staff Member

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    The process of fiberglass molds is something completely new to me, so sorry if the questions are green :oops: Here comes another :) So this picture below is the plug that you are pulling from? [​IMG]
    I am guessing that you lay the fiberglass over the grey area and pull from the polished outside of this plug.
    What has me confused is that in this picture below its the outside of the cowling that looks polished like it was pulled from the inside of the plug to get that nice surface.
    [​IMG]
    Once again pardon the ignorance I am new to all of this but very interested.
    Thank you
    Mark and Trish
     
  12. Helno

    Helno Member

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    The grey plug is used only once to make the red mold. After that you make the actual parts from the red mold.
     
  13. kram242

    kram242 Administrator Staff Member

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    Ahh I see now thank you Helno.
    I am glad to see you posting this, I have been wanting to try and make blades for a wind turbine, and this would be a great way to do it. I am sure I will be calling on you for more help as we get it underway. Thanks again and keep up the good work.The new next cowling you guyz are working on looks great!
    Mark and Trish
     
  14. SilverFox

    SilverFox Member

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    Very cool, thanks for sharing. What kind of plane is it for?
     
  15. dewsy

    dewsy New Member

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    The mould was made for a Youngster kit by Fisher Flying Products. http://www.fisherflying.com/index.php?o ... 3&Itemid=5
    The next one is totally custom.
    The making of a negative mould allows material layers to be added as needed including stiffeners when needed and have a nicely finished outside surface without addition of faring fillers(something like bondo). The only reason to lightly sand the part is to produce a texture that paint will adhere to. If a colour gel coat is applied in the mould before lamination is done then the part is completely done when pulled.
     
  16. kram242

    kram242 Administrator Staff Member

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    Yoram and ET these are awesome! thank you
    I am going to move these into a new thread.
    Mark and Trish
     
  17. Helno

    Helno Member

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    Here are some pictures of one of the installed cowls.



    Attached files [​IMG] [​IMG]
     
  18. thunder hawk

    thunder hawk Member

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    That is one pretty airplane. :cool:
     
  19. rcav8r

    rcav8r Moderator Staff Member

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    WOW... That's nice.
     
  20. Helno

    Helno Member

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    It's a little fancier than mine.


    That is user Dewsy from here in the cockpit.
    Attached files [​IMG]
     
  21. thunder hawk

    thunder hawk Member

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    That looks like a fun ride. I like the V tail. :D
     
  22. PAULE

    PAULE Member

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    :banger: :byei: :dance3: :fugly: :doubleup: GREAT JOB
     

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