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Date: Fri, 06 May 2005 22:01:06 -0500
From: Charlie England <ceengland@bellsouth.net>
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To: Rotary motors in aircraft <flyrotary@lancaironline.net>
Subject: Re: [FlyRotary] Re: Duct Nearly Finished
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Ed Anderson wrote:

> No! Steve!, No!  Never! {:>).  Actually, I have come a ways since I 
> made my first horrid attempt at fiberglass work.  I used to spend a 
> week on the mold, Paint it with mold separator, wax it, etc.  Then 
> mainly because of the shapes ended up having to destroy the mold to 
> get the product.  First breakthrough was use of duct tape - but still 
> ended up with foam mold mainly destroyed. So know I use a type of 
> "tan" foam that epoxy does not destroy, carve the shape with rasp and 
> a brush with stiff brass bristles and slap the fiberglass directly on 
> the foam.  For ducts, its nice because then I can shape the foam 
> internally to get  exactly the curve I want.  Fiberglass does have 
> advantages in many cases.
>  
> But, don't think a large scale composite project is even on the 
> distant horizon {:>)
>  
> Ed
>  
>  
>
>     ----- Original Message -----
>     From: Steve Brooks <mailto:prvt_pilot@yahoo.com>
>     To: Rotary motors in aircraft <mailto:flyrotary@lancaironline.net>
>     Sent: Thursday, May 05, 2005 7:04 AM
>     Subject: [FlyRotary] Re: Duct Nearly Finished
>
>     Ed,
>     It sounds like you're becoming quite handy with fiberglass.  You
>     may be ready to start a composite project.
>      
>     Steve Brooks
>      
>
>         -----Original Message-----
>         From: Rotary motors in aircraft
>         [mailto:flyrotary@lancaironline.net]On Behalf Of Ed Anderson
>         Sent: Wednesday, May 04, 2005 9:44 PM
>         To: Rotary motors in aircraft
>         Subject: [FlyRotary] Duct Nearly Finished
>
>         Got the new duct nearly finished.  Just need to pop rivet the
>         hinge halves on it, sand some of the worst bumps off, paint it
>         and put it on.  Then ready to go fly and try out the new duct
>         and engine.  Took two days, to make the mold, fiberglass the
>         outside and contour the inside for that trumpet shape - it
>         would have taken me two weeks 5 years ago - but still prefer
>         metal {:>).
>          
>         Now just have to whip up a combination filter holder and
>         Plenum and I'm done with mods for the summer (I think).
>          
>         Tracy got the apex seals for analysis but just headed out to
>         Colorado like he had planned rather than postpone his trip to
>         play with the seals - just don't know about some folks {:>).
>          
>         Sure makes me wonder why airline builders use all of those
>         expensive circuit breakers rather than cheap fuses - must be
>         something I'm missing.  Fortunately, we have the right to make
>         the choice that suits our preferences (and pocket book).
>          
>         Ed
>          
>         Ed
>         Ed Anderson
>         Rv-6A N494BW Rotary Powered
>         Matthews, NC
>         eanderson@carolina.rr.com <mailto:eanderson@carolina.rr.com>
>
Have you considered just using foam itself as the duct (w/o the glass)? 
Rumor has it that Jim Bede's latest cash extractor uses solid foam 
control surfaces.

Charlie