Constructing your own fibreglass mold Page
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By Tony Rogers |
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This
method was developed over several models to produce a fiberglass
fuselage cheaply by anyone with a few basic skills and can
result in a good model very quickly
Whether you start with a commercial plan or one of your
own it does not matter the basic requirement is the same. A
profile shape of the fuselage from above and from the side and
some section shapes along the length
of the fuselage about 4-6” apart.
Material required :
-
A
piece of RHS steel about 1” square and about two feet
longer than the fuselage plus some means of supporting it at
each end. I have a stand on wheels at each end with a piece
of pipe into which the RHS goes with a hole drill at right
angles through the RHS and pipe at one end so a rod,
screwdriver etc can be put through the holes and lock the
RHS in any position.
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3/8
MDF board ( known in NZ as Custom wood)
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1/8
MDF board
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Glue
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Preferably
a small nail gun firing 1” X 1/16 nails
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Wallboard
filling compound (
this is the product used to “stop” or fill the joints
etc on the interior wall boards of houses. It comes in
different “set” times I use 45 minute it allows you to
do a reasonable amount before it sets off . This is a
“Plaster of Paris” type material mixed with water.)
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Fibreglass
materials of your choice ( Polyester or Epoxy and their
parting agents etc)
To
start cut 2 complete profiles side and top views of the fuselage
from 3/8 MDF. Cut these 1/8
smaller than the plan around the outer edge. Remove a 1” strip
from the centerline of each piece
of the 4 pieces. Now join the like pieces together by
screwing (not gluing) with the screws no closer than 2” from
the outside edge. You should now have a top, bottom and a left
and right . Glue with epoxy all 4 pieces around the RHS and you
have the basis of the fuselage. Cut the section shapes once
again 1/8 smaller around the outer edge and 3/8 smaller on each
side of the right angle to allow for the thickness of the
previously made profiles. Glue these sections onto the profiles
in the appropriate place and it should look something like photo
# 1
Cut
into strips the 1/8 MDF about 3/8” wide and start planking the
fuselage frames gluing and nailing as you go. This does not have
to be pretty you will find the strips will just about find their
own position but try to keep it “Fair” working from the center
inwards and leaving about 1/8 gap between the strips. It
should be looking like photo # 2
Before totally covering with the strips I stuff the interior with
newspapers just to stop the filler all running right through the
gaps you should be ending up with something like photo # 3
Mix
up a batch of filler and with a trowel force it through the gaps
between the strips and build up a layer over the whole fuselage.
This goes on very quickly and sets off fairly quickly so only
mix what you can handle, experience will soon tell you this but
the price of the product means it does not matter if you waste a
bit Photo # 4 is
what you are aiming for.
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