[Mike Emilio]

Yes, this black stuff, and I'm not really sure what it is, , , , is right on top of the PVA.

It's a polyester of a sort, so I think it's just a mixture of regular gelcoat with alot of styrene mixed in to water it down. You can tell it has alot of styrene in it, because the odor is 10x stronger than the regular Canadian Tire stuff, and it clogs up the sand paper.

I'll order some of that other stuff you use and test it out.
But not on this project.

Anyways, , , It's almost midnight. I've been at this now for the past 6 hours straight.

This plug is about 11 feet long!
I got 4 layers down. Took about 3 gallons of resin, and that's just the top!

Normally I'd put in some strengthening material like a Clegcell, or even Divini-cell, A heavy biased ply cloth is also really good, but there's just no money budgeted for more materials.

I'm really bushed.
Time for a hot chocolate and some sleep. ZZzzzzzz

[Mike Emilio]

Jeremy, , ,

What kind of spray gun do you use.

Mine is a Binks 2001 gelcoat and resin spray gun.
It has automatic regulating and atomizing of the MEKP at 2%.
I run it at a steady 90 psi.

I simply change the nozzles and needle for either gelcoat, or resins.

The whole system set me back about $1,200 maybe 6 years ago. Probably cost a bunch more today.

The only hassel, if it is one, is that it takes a gallon of solvent to flush the whole system out, and about 1 hour or so for cleanup.

Sometimes I don't clean it out for a week, or until the job is done.

---------
edited, , ,

I just re-read that your spraying Endura.
That's a Urethane so I guess your using an automotive type of spray gun?

--------
After 2:00am! Now I'm really beat!

[bbbair]

Guys;

I have been following this thread with great interest - mainly because of my historical interest in the Arrow and my awe of the size of this model.

Now; I am facinated by the amount of work that is required to make a fiberglass plug/mold/model. I am gaining a whole new respect for what it takes to make one of these and the folks that do it.

Keep up the good work and I look forward to seeing at least ONE of these giant Arrows up front and personal.

Good Luck to all envolved!

[Mike Emilio]

bbbair, , ,

My rule of thumb is to only build something if there's no kit available, or if there is a kit, the price might be very restrictive $$.

Some may already know that I have a web site of exotic plans. I try to keep the selection to the above rule of thumb.

When you think about how long it takes to scratchbuild something like this out of wood, or take it even further into the molding stage, you'll soon realize that a $1,000 or so kit is a real bargain!

If this were contracted out, it would most likely be in the area of $35,000-$40,000. That's considering all the equipment needed, literally hundreds of manhours, and the overhead costs of a big floor space.

In my scenario here, I'm doing this for 2 main reasons:

a). Simply because it falls into the very rare category, and,
b). I have an arrangement with Brad for model hmmm, that I'm interested in. Can't say what it is, but it's gonna be another cool jet.

[Guest]

Hi Mike,
Keep in mind I'm not spraying the same stuff that you just did, but I primarily use a Sata RP3000 digital for all of my base/clear work. Depending on where you buy them and what kind of discount you get, the digitals are around $750 to $1000, the non digital is about $550 to $700. It uses a 1.3mm tip and that works for most of what I spray, all my base coat, clear coats, even most high build primers like the K36 and K38. When I spray the Slick Sand though, or a completely unreduced high build primer, I use my Sata KLC primer gun with a 2.4mm tip. Those guns were around $325 when I bought mine. I generally spray at 30psi at the gun. With the RP3000 if I mix my K38 4:1:1 it lays out like glass, no texture at all which makes sanding incredibly quick and easy. The KLC primer gun of course leaves a bit of a texture but the product I spray with that gun is very thick so the atomization is not exactly what I'd call smooth haha.
For my clear coats, using the RP3000 with the 1.3 tip and about 34psi at the gun gives me a near perfect finish, almost zero orange peel in the clear. The RP is a reduced pressure gun, kind of half way between a conventional gun and HVLP. You get less overspray with it and the paint lays out smoother than I've seen with any other gun.
Again, it's all different application here, but I think the general principal is the same.
Anyway, as with everything, what I've talked about has worked for me in the past, but I'm no expert in plugs and molds, do some experimenting with the products I've mentioned. Only downside is the DU1000 is expensive, it seems to me the clear is around $250 or $300 a gallon, and the DU5 is in the neighborhood of $200 per quart, when you're mixing 1:1 that add's up really quick.

Originally Posted by Mike Emilio

Jeremy, , ,

What kind of spray gun do you use.

Mine is a Binks 2001 gelcoat and resin spray gun.
It has automatic regulating and atomizing of the MEKP at 2%.
I run it at a steady 90 psi.

I simply change the nozzles and needle for either gelcoat, or resins.

The whole system set me back about $1,200 maybe 6 years ago. Probably cost a bunch more today.

The only hassel, if it is one, is that it takes a gallon of solvent to flush the whole system out, and about 1 hour or so for cleanup.

Sometimes I don't clean it out for a week, or until the job is done.

---------
edited, , ,

I just re-read that your spraying Endura.
That's a Urethane so I guess your using an automotive type of spray gun?

--------
After 2:00am! Now I'm really beat!

[Mike Emilio]

Originally Posted by LGM Guitars

Hi Mike,
, , , ,
, , , ,

Anyway, as with everything, what I've talked about has worked for me in the past, but I'm no expert in plugs and molds, do some experimenting with the products I've mentioned. Only downside is the DU1000 is expensive, it seems to me the clear is around $250 or $300 a gallon, and the DU5 is in the neighborhood of $200 per quart, when you're mixing 1:1 that add's up really quick.

That is expensive, , , , but I'm kinda curious now to try it out.
I'm going to place an order for some.

[Mike Emilio]

And now to cut it out.
So far, the front and rear are absolutely perfecto!

[Mike Emilio]

Moo came over to get a Flite-Metal sample for himself and Sammy.

He gave me a hand getting the plug out.

It literally fell apart, no coaxing at all.

It's perfect!
(But I already kinda knew it would be, he he he. No Canadian Tire stuff here.)

Not yet trimmed and cleaned up, , , , but Eric was totally amazed.

Probably take 3-4 days for dressing this big boy, and to add in all the additional tidbits.

A few shots with Eric
.

[maddog]

LOOKING GOOD Mike, just a fine job .Call you sun nite. Brad "Maddog" Metcalf

[Guest]

....No hard Feelings Mike..