Mailing List flyrotary@lancaironline.net Message #11017
From: paul <sqpilot@bellsouth.net>
Subject: Re: [FlyRotary] Re: foam-sicle (new ducts)
Date: Wed, 1 Sep 2004 21:13:35 -0500
To: Rotary motors in aircraft <flyrotary@lancaironline.net>
Message
 
----- Original Message -----
Sent: Wednesday, September 01, 2004 6:39 PM
Subject: [FlyRotary] Re: foam-sicle (new ducts)

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...)
 
Hey, Rusty....I have heard rumors that you hate fiberglassing. On the other side of the coin....how long do you think it would take you to make all those compound curves out of aluminum?    Yes, you seem to get better and better with each fiberglass job.....I think you are really a closet fiberglasser, and afraid to admit it.  Looks good, Rusty.  I hope you are rewarded with excellent cooling from these scoops.   Paul Conner
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