Mailing List flyrotary@lancaironline.net Message #11005
From: Russell Duffy <13brv3@bellsouth.net>
Subject: RE: [FlyRotary] Re: foam-sicle (new ducts)
Date: Wed, 1 Sep 2004 18:39:56 -0500
To: 'Rotary motors in aircraft' <flyrotary@lancaironline.net>
Message
Heah! I missed something!  How’d you do that?

TJ<><

 

 
Everytime I do this silly foam molds, I get a little better at it. 
 
This time, I used that green craft foam that Wal-Mart sells, which must be about the easiest thing in the world to sand.  It's almost too soft actually, though it won't seem that way when I'm trying to chip it out through the open holes.  The other tool I've added is the belt sander.  Used carefully, it makes very short work of the shaping.  If you can set up a big fan behind you, blowing at the sander, the cloud of dust exits the hanger nicely (best performed when you're neighbors aren't around). 
 
The round ends were cut with a hole saw, that happened to have about the right ID. 
 
The glued in sticks are an improvement from when I built the last airbox/plenum thing I had.  I learned that it's pretty hard to work with a piece that has wet glass all around it.  Now I have a handle :-) 
 
As you can see, it's now 6:30 central, so I won't be doing any glassing today.  I do have all the pieces cut, as well as having everything else ready to go.  I'll attempt to put on 3 layers in the morning, using fast hardener (air conditioned garage), then put however many more layers I feel like I need later in the day. 
 
Cheers,
Rusty (will the fun ever end...)
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