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Date: Mon, 11 Apr 2005 15:38:25 -0500
From: Charlie England <ceengland@bellsouth.net>
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To: Rotary motors in aircraft <flyrotary@lancaironline.net>
CC: "Kerr, Bernie" <jbker@juno.com>
Subject: Re: [FlyRotary] Re: SQ2000 flying again
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Richard Sohn wrote:

>  
>
>     ----- Original Message -----
>     From: Russell Duffy <mailto:13brv3@bellsouth.net>
>     To: Rotary motors in aircraft <mailto:flyrotary@lancaironline.net>
>     Sent: Monday, April 11, 2005 5:53 AM
>     Subject: [FlyRotary] Re: SQ2000 flying again
>
>     Did you see Richard Sohn's trick for making a fiberglass tube at
>     Shady Bend? Basically you overfill a section of an inner tube with
>     sand. Once filled you can bend and shape it. Glass it. Remove the
>     sand. Peel out the inner tube. Bingo. A perfectly smooth
>     fiberglass duct of the correct dimensions and shape.  
>      
>     Hi John,
>      
>     I heard about that, or read it somewhere, but never got around to
>     trying it.   Seems like it would need to be attached in place on
>     the engine to make sure it was in the proper shape, but I don't
>     have room to work around all the other stuff to try to glass it
>     there. 
>      
>     Now I could fill the hose with Sakrete and sand, then put some
>     water in it before putting it in place.  Once hardened, you could
>     take it away, and glass it on the bench.  Of course you'd have to
>     put a couple layers on, then cut it apart to get it off the
>     concrete tube, but you could easily put another layer on it go
>     glue it back together.   
>      
>     Maybe I'll just keep putting this off :-)
>      
>     Cheers,
>     Rusty
>      
>     I have to clarify some thing on the fiberglass mold.
>     I made a plug out of styro foam and painted it with water base
>     Latex until it was smooth. When it was dry I coated it with mold
>     release(PVA) and than wrapped the fiberglass around. I am using
>     mostly VE for the convenience vs Epoxy. So I have to be careful
>     not to expose the foam to the resin. When it is cured, I heat the
>     whole thing with a heat gun until the foam shrinks and takes the
>     Latex with it. I is getting small and soft enough to just fall out
>     of the FG with the inner surface as smooth as the plug was to
>     begin with, and no mess with gas and melted foam.
>      
>     Richard Sohn
>     N-2071U
>      
>      
>
The sand/bike inner tube is Bernie Kerr's trick.  I'm cc'ing him to ask 
if you need something in addition to the sand to make it hold its shape.

Charlie