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  #361  
Old 05-06-2019, 06:20 AM
RV7ForMe RV7ForMe is offline
 
Join Date: Jul 2015
Location: Europe
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Default Cool beans!

Very nice! We attached the Vans part to the other 7 and like you said the fit was horrible. I wonder if I should just delete the part and save the money on my fuselage order... your looks much better even before sanding. Keep up the good work and thanks for sharing!
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  #362  
Old 05-06-2019, 11:08 AM
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kentlik kentlik is offline
 
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Hey Jereme, I suggest you pull a mold off of it after you have completed it.
I would be more than happy to help you do that. That way I can get a better product for my plane!
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  #363  
Old 05-06-2019, 07:53 PM
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jcarne jcarne is offline
 
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Location: Worland, Wyoming
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Quote:
Originally Posted by vernh59 View Post
Nicely done! Interested in the final product.
Thanks Vern!

Quote:
Originally Posted by RV7ForMe View Post
Very nice! We attached the Vans part to the other 7 and like you said the fit was horrible. I wonder if I should just delete the part and save the money on my fuselage order... your looks much better even before sanding. Keep up the good work and thanks for sharing!
No problem at all. It will definitely be faster to just chop up the Van's fairing and reglass certain areas if you decide to go that route. However, if you want to learn how to do a bit of fiberglass in the process it seems like a good way of doing it. If you ever have questions just drop me a line!

Quote:
Originally Posted by kentlik View Post
Hey Jereme, I suggest you pull a mold off of it after you have completed it.
I would be more than happy to help you do that. That way I can get a better product for my plane!
haha I bet you would! Pulling a mold off of this guy would be a real treat as it is pretty springy at the back when it is not on the plane, it would be tough to get it in the right spot to make a mold.
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  #364  
Old 06-10-2019, 07:16 PM
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jcarne jcarne is offline
 
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Well after taking a month off for trips and sickness I'm back at it! My summer is in full swing and I'm planning on logging 8ish hours a day. My goal for the summer is to get as much of the fiber glass and canopy done as possible.

First up, I continued working on the empennage fairing. This thing is turning out to be emensly time consuming but oh well, good practice and I should get superior results. I did not like how the tails of the fairing came out on the first lay up so I did some sanding, forming, and layed up some new ones. These ones came out so much better!

20190608_141814 by Jereme Carne, on Flickr

Next I had to extend the front portions down and aft an inch or so.

Fiber glass is quite fun when you take an ugly beast like this...

20190610_140304 by Jereme Carne, on Flickr

...to this! That Dremel Saw Max I got works great on fiberglass!

20190610_143508 by Jereme Carne, on Flickr

I also continued working on the tips for the elevators and rudder. I sanded the gel coat off of part of the tips since I plan on bonding them to control surfaces. Extra work? Absolutely! Personal preference that bonding looks better? Yup!

I also made backer strips out of 0.025 and bonded them in with epoxy.

20190610_140248 by Jereme Carne, on Flickr

Finally, I am slowly working off and on on the canopy. I made the C-791 canopy skirt braces. These took a fair amount of time with deburring.

20190608_163510 by Jereme Carne, on Flickr


Glad to be back in the garage getting things done! A few more days on tips and fairing and I will be in full swing on the canopy.
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Last edited by jcarne : 06-11-2019 at 09:37 AM.
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  #365  
Old 06-19-2019, 06:35 PM
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jcarne jcarne is offline
 
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The fiberglass work continues! After the empennage fairing was all laid up how I liked it it was time to lay on some micro. As you can see in the pic I should have got it a bit more on the dry side but it worked out just fine.

20190611_123511 by Jereme Carne, on Flickr

Once the micro was cured it was off to the races with sanding blocks. I used these blocks with great results. Spray adhesive and sandpaper of choice was used (mostly 80 grit).

This is it after sanding, pretty ugly so far eh?

20190614_215244 by Jereme Carne, on Flickr


After the main sanding I located and drilled the screw holes I wanted and went ahead with countersinking. Then I laid down a bead of epoxy with cab-o-sil on all the seams after taping the tail yet again. The epoxy mixture squeezes out and bingo bango you got a perfect conforming edge. Next I did four coats of epoxy brushed on and squeegeed off with a credit card to fill pinholes. Once cure there was a bunch more sanding to make it perfectly smooth and get rid of any marks/pinholes.

...and finally the day had arrived, priming.


20190618_145531 by Jereme Carne, on Flickr


All in all it came out great and I'm really happy with it! It was a great learning experience and I feel I am now fairly competent with fiberglass. A big shout out to Dan Horton for his awesome posts on how to do fiberglass!

One more shot of the fairing on the plane.


20190619_122951 by Jereme Carne, on Flickr


P.S. I also got the tips bonded and primed onto the rudder and elevators but I will just let this post sink in for a few days first.
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  #366  
Old 06-21-2019, 10:20 AM
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AndyRV7 AndyRV7 is offline
 
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That looks like nice work!
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  #367  
Old 06-21-2019, 04:58 PM
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jcarne jcarne is offline
 
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Quote:
Originally Posted by AndyRV7 View Post
That looks like nice work!
Thanks good sir!
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  #368  
Old 06-22-2019, 04:41 PM
RV7ForMe RV7ForMe is offline
 
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Default I want one...

Alright! Are you making me one also? Looks like you are having way to much fun Good Job!
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  #369  
Old 06-24-2019, 10:47 AM
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jcarne jcarne is offline
 
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Quote:
Originally Posted by RV7ForMe View Post
Alright! Are you making me one also? Looks like you are having way to much fun Good Job!
haha thank for the compliments! I'm gonna need a few years off before I even think about more mold-less fiberglass work.
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  #370  
Old 06-29-2019, 11:13 AM
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jcarne jcarne is offline
 
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Ok I finally finished all the tips and here are the results. I strongly recommend to people to do the tips when the weather is warm (unless you have a heated shop) and don't wait until the plane is almost done. The tips take a lot of time, way more than a person thinks. If my plane was almost done and I had to drop this many hours to finish them I might have cried. haha However, if you aren't blending them in like I did it will take way less time.

First, I laid fiberglass anywhere it was needed (elevators).

20190612_155246 by Jereme Carne, on Flickr

After curing and sanding the elevator tips I laid down a 2" wide layer of fiberglass that is only 0.003" thick, very thin stuff indeed.

20190611_161559 by Jereme Carne, on Flickr

After curing and sanding the taped seam I then put a nice coat of micro on the whole thing.

20190612_155238 by Jereme Carne, on Flickr

After curing and sanding the micro I switched to Evercoat Rage Gold. This stuff is ready for sanding in about 20-30 minutes instead of a day as with micro. Some may scoff at using this stuff but I know many people that have used this and there planes have been flying with it for a long time. To be honest I don't even know why a few peeps have beef with this stuff? I personally would highly recommend it and it's meant for fiberglass too.

20190617_101139 by Jereme Carne, on Flickr

Here sanding is almost finished. Looking pretty good.

20190617_180404 by Jereme Carne, on Flickr

Next it was on to the VS and HS tips. First you need to close out the tips. There are many different ways to do this but I chose to use some flat layup I had out of 4 plies of 8.9 ounce. Shape it to fit, 5 min epoxy it in the correct spot and then I put a bead of flox on the inside with two more layers on top of that to really seal it up.

20190624_141921 by Jereme Carne, on Flickr

Nice I put a coat of micro on the area shown and epoxied in the metal backing strips. Van's doesn't tell you to put a metal strip there but after countersinking the fiberglass it is quite thin where the rivets go through.

20190624_212039 by Jereme Carne, on Flickr

After curing and sanding I put a layer of Rage Gold on. Almost all of this got sanded off in the end.

20190625_110728 by Jereme Carne, on Flickr
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