Return-Path: Received: from [216.52.245.18] (HELO ispwestemail1.mdeinc.com) by logan.com (CommuniGate Pro SMTP 4.2b3) with ESMTP id 84107 for flyrotary@lancaironline.net; Sat, 22 May 2004 10:31:03 -0400 Received: from 7n7z201 (unverified [67.136.146.25]) by ispwestemail1.mdeinc.com (Vircom SMTPRS 3.1.300.2) with SMTP id for ; Sat, 22 May 2004 07:30:57 -0700 Message-ID: <0c5a01c44009$633641c0$c8918843@7n7z201> From: "William" To: "Rotary motors in aircraft" References: Subject: Re: [FlyRotary] Fiberglass Help! Date: Sat, 22 May 2004 09:30:43 -0500 MIME-Version: 1.0 Content-Type: multipart/alternative; boundary="----=_NextPart_000_0C55_01C43FDF.74312050" X-Priority: 3 X-MSMail-Priority: Normal X-Mailer: Microsoft Outlook Express 6.00.2800.1409 X-MimeOLE: Produced By Microsoft MimeOLE V6.00.2800.1409 This is a multi-part message in MIME format. ------=_NextPart_000_0C55_01C43FDF.74312050 Content-Type: text/plain; charset="iso-8859-1" Content-Transfer-Encoding: quoted-printable You probably only need 2-3 layers of BID, buy it as sheet,=20 The technique I use to avoid too heavy a layup is: Buy some 2 mil plastic material, cut out a sheet twice the size of your = layup, fold in half, mark the shape of what you want the finished piece = to look like with felt tip marker, weigh the plastic, turn the plastic = over, lay down number of plies of BID desired, fold the plastic over the = bid (make a sandwich of plastic, cloth, plastic) weigh the plastic/cloth = combo, subtract the weight of plastic to get the weight of cloth, mix an = equal weight of epoxy and pour onto cloth. Lower the plastic back into = place, and squeegee / roll the sandwich until you can see the marker = through the sandwich. squeegee out the excess epoxy and then cut with a = rotary wheel cutter on the lines. Now you can peel off ONE side of the = plastic, carry it to your tape covered foam piece, position it, and peel = off the other side. Apply sheet peel-ply and brush it down using a hair = dryer to remove excess epoxy and let cure. Bill Schertz KIS Cruiser # 4045 ----- Original Message -----=20 From: Ed Anderson=20 To: Rotary motors in aircraft=20 Sent: Saturday, May 22, 2004 8:51 AM Subject: [FlyRotary] Fiberglass Help! Ok, you fiberglass types. I need some guidance. I can (and have) = slapped resin on glass cloth and obtained a functional (if heavy) item. = However, I am about to start work on my new radiator ducts and I would = like to do better. My ducts will be approx. 4"x4" at the inlet and = approx. 9"x10" at the core. There might be as much as 1 psi pressure on = the walls (if I should ever be so lucky to go that fast).=20 There a some semi compound curves at the corners of the duct as it = slopes inward from the top and bottom from the core to the inlet. =20 I need your recommendation about the weight and weave of the cloth. I = have previously used the cloth tape as it was easy to manage, but it = required several layers and it is a bit heavy. Like I said functional = but not pretty nor light. I would like your guidance on how best to apply the sheet to the mold. = In the past, I basically wrap the foam mold in duct tape and the lay = resin on it followed by raps of the cloth tape and more resine. I am = told that using sheet rather than the tape and first laying it out on = aluminum foil to wet it and then cut it in sizes say to fit a side of = the 4 side foam mold with a bit for overlap with the adjacent sides was = one way to go. Any suggestions would be appreciated. Ed Ed Anderson RV-6A N494BW Rotary Powered Matthews, NC ------=_NextPart_000_0C55_01C43FDF.74312050 Content-Type: text/html; charset="iso-8859-1" Content-Transfer-Encoding: quoted-printable
You probably only need 2-3 layers of = BID, buy it as=20 sheet,
 
The technique I use to avoid too heavy = a layup=20 is:
Buy some 2 mil plastic material, cut = out a sheet=20 twice the size of your layup, fold in half, mark the shape of what you = want the=20 finished piece to look like with felt tip marker, weigh the plastic, = turn the=20 plastic over, lay down number of plies of BID desired, fold the plastic = over the=20 bid (make a sandwich of plastic, cloth, plastic) weigh the = plastic/cloth=20 combo, subtract the weight of plastic to get the weight of cloth, mix an = equal=20 weight of epoxy and pour onto cloth. Lower the plastic back into place, = and=20 squeegee / roll the sandwich until you can see the marker through the = sandwich.=20 squeegee out the excess epoxy and then cut with a rotary wheel cutter on = the=20 lines.  Now you can peel off ONE side of the plastic, carry it to = your tape=20 covered foam piece, position it, and peel off the other side.  = Apply sheet=20 peel-ply and brush it down using a hair dryer to remove excess epoxy and = let=20 cure.
Bill Schertz
KIS Cruiser # 4045
----- Original Message -----
From:=20 Ed=20 Anderson
Sent: Saturday, May 22, 2004 = 8:51=20 AM
Subject: [FlyRotary] Fiberglass = Help!

Ok, you fiberglass types.  I = need some=20 guidance. I can (and have) slapped resin on glass cloth = and obtained=20 a functional (if heavy) item.  However, I am about to start work = on my=20 new radiator ducts and I would like to do better.  My ducts = will be=20 approx. 4"x4" at the inlet and approx. 9"x10" at the core.  There = might=20 be as much as 1 psi pressure on the walls (if I should ever be so = lucky to go=20 that fast).
 
There a some semi compound curves at = the corners=20 of the duct as it slopes inward from the top and bottom from the core = to the=20 inlet. 
 
I need your recommendation about the = weight and=20 weave of the cloth.  I have previously used the cloth tape as it = was easy=20 to manage, but it required several layers and it is a bit heavy.  = Like I=20 said functional but not pretty nor light.
 
I would like your guidance on how = best to apply=20 the sheet to the mold. In the past, I basically wrap the foam = mold in=20 duct tape and the lay resin on it followed by raps of the cloth tape = and more=20 resine.  I am told that using sheet rather than the tape and = first laying=20 it out on aluminum foil to wet it and then cut it in sizes say to fit = a side=20 of the 4 side foam mold with a bit for overlap with the adjacent sides = was one=20 way to go.
 
Any suggestions would be=20 appreciated.
 
Ed
 
 
Ed Anderson
RV-6A N494BW Rotary=20 Powered
Matthews, NC
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