[excelsiuss]

What do you plan to do for the formers John? Will someone be batch cutting them for you by laser? What thickness do you think will be needed.

Pete

[Dutkoski]

Formers will be kept to a minimum. In my smaller Arrow, which is fully composite, there is only one fuselage former which the wingspars tie into. This kept the model light and the build quicker. I woukd like to carry on that concept with this build. So far, there will be the two main fuselage formers that the two wing spars will get locked into and there will be a former at the rear, at the panel line where the tailcone meets the fuselage. I suspect there will also be a former just ahead of the main hatch which will help the fusealge keep it's shape.

In the forward fuselage, a former near the area where the radome meets the fuse and of course in front of the nose gear retract location to help support the mount structure. Outside of some small partial formers, that's about it. Except for the two main formers, the rest will be 1/8" aircraft grade plywood. The main formers which will be structural, will be two laminations of 1/4" plywood with carbon fiber cloth front and back where the spar plates get attached but left as 1/4" below.

The spars will be aluminum, 3/16" thick and the capture plates will built up aluminum that will get bonded and bolted to the two main formers.

As far as lazer cutting, don't know yet, depends on how many sets I will need to make. I have a full woodworking shop, so cutting the parts isn't much of an issue for me. I really don't think there will be that many sets required though.

[Dutkoski]

Just one other thing, there will be some parts assembly done by me to help out anyone who wants one, the two intake nacelles will be assembled and the tail cone will be assembled. These are fiberglass and kinda difficult if you are not too familiar in doing it. To assemble the tail cone parts, you have to be a bit of a contortionist.

The mould for the inside of the tail cone is made and the two fiberglass cones are also made. Here the tail cone parts are fitted, I'll bond them in this afternoon, apparently I have to put up a Christmas tree, the duties of a husband are never ending 😎

[HAL9KPCM]

Originally Posted by Dutkoski

I'll bond them in this afternoon, apparently I have to put up a Christmas tree, the duties of a husband are never ending 😎

Just stand up the fuselage, wrap some lights around it and call it done.

[Trumpetman]

Originally Posted by HAL9KPCM

Just stand up the fuselage, wrap some lights around it and call it done.

[Dutkoski]

That's what I normally do Dave, which is fairly easy. But the main fuselage is 81" long and the ceiling in my basement workshop is 82". For those who have a lower ceiling, it might be a problem. But, the laminating of the 6 oz. cloth patches beween the inner cones and the tail cone stinger extension was actually easier than anticipated.

Yesterday I laminated a sheet of carbon cloth in the area where the turbine will get mounted, turned out it took a piece 22" X 24" to cover the bottom and wrap up the sides to over lap the carbon wing root area. Turned out it substantially stiffened the fuselage area. The lower fusealge is flat and being this size, it's quite flexible. I will need to laminate "something" in this area to stiffen up the fiberglass yet not increase the wieght by much, most likely will vacuum bag some balsa ribs strips, like they use in canoe bottoms.

[Dutkoski]

The tail cone is pretty much done, a final bit of polyester resin filler has been applied to the seams, very pleased as far as the fit goes. Weighed the fusealge today, with the installation of the two inner exhaust cones, the tail cone stinger extention and the 22" X24" sheet of carbon fiber cloth inside the fuse, it now weighs 5 lbs 11 oz's.

[Dutkoski]

While sanding the tailcone, was tired of trying to see all the little oops. So, found some basic automotive primer and gave the area a shot of grey. Now, all the little issues can be clearly seen. Plus, it looks a lot better with some colour.

[excelsiuss]

with all the pinholes, Wouldn't that make it lighter.

Looks great John!

[Dutkoski]

If you have pin holes, you have to fill them before painting. These occur when you try and lay up a part using only one layer of fiberglass cloth. That is why I always use two, the light two oz cloth goes on first, this will eliminate the pin holes if you use the proper quantity of resin. Also, the part is weaker.

I attached the front fuselage to the main section. To increase the clamping pressure between the surfaces, you temporarily install screws and plywood washers on both sides. This distributes the pressure and increases the gluing surfaces. Makes for a very strong joint.