VansAirForceForums  
Home > VansAirForceForums

- POSTING RULES
- Donate yearly (please).
- Advertise in here!

- Today's Posts | Insert Pics


Go Back   VAF Forums > Model Specific > RV-6/6A
Register FAQ Members List Calendar Today's Posts

Reply
 
Thread Tools Search this Thread Display Modes
  #11  
Old 01-14-2011, 02:24 PM
flytoboat's Avatar
flytoboat flytoboat is offline
 
Join Date: Dec 2006
Location: Collinsville, IL
Posts: 620
Default

Quote:
Originally Posted by erich weaver View Post
The coolest thing is that you have modified the cowling so that the front air inlets are no longer split between the top and bottom cowling - They go with the bottom only (see last photo). Nice dude.

Erich
Check out "From The Ground Up" (episode 10 I believe) to see another way to do this. He also used a plenum and modified the front of the cowling. Any one know the pros/cons of doing this?
__________________
Don
VAF #1100, EAA864
-6A bought flying
Reply With Quote
  #12  
Old 01-14-2011, 08:17 PM
miyu1975's Avatar
miyu1975 miyu1975 is offline
 
Join Date: Apr 2008
Location: Indianapolis, IN
Posts: 1,069
Default

very interested as to how you started the process, what mold did you use to make plenum?
__________________
Ryan Allen, CFII

RV7 N612RA, flying since july 2012
E-170/175
RV10 Tail Kit complete, Wings 90%, fuse on order
Acro Sport 2, building
Reply With Quote
  #13  
Old 01-15-2011, 01:22 AM
whittfic's Avatar
whittfic whittfic is offline
 
Join Date: Apr 2007
Location: Auckland, New Zealand
Posts: 128
Default

Geez thanks people, I am getting a little swell headed here with all the nice comments!

How was it done? Unfortunately I didn't document the process or take any progress photos, so I will try to explain what I did as best I can. It might seem a little lengthy tho', so if you feel your eyes starting to glaze over I wont be offended if you hit delete and move on.

I started by taking a quick mould off a section of the Vans supplied top cowl to get the basic shape. I cut and bonded this to flat pieces of wood that were clamped to the inside surfaces of the fitted baffles (I'm starting to form a pattern or replica here of the finished product). I then removed this semi-formed pattern from the baffles/engine assembly, braced it and cleaned it up sufficiently to take another mould (remember, I haven't started forming the inlet shapes yet). I formed the corner radii in this mould using nothing more than auto filler and a suitably sized socket from my tool collection.

More sanding and cleaning up, then I made a rough 'plenum' from this mould still without inlets. This was trimmed and fitted to the engine, ensuring there would be enough clearance under the upper cowl. Rigid urethane foam was then used to form the shape of the inlets. The trick here was to fit and size the blocks of foam so that when the cowls were in place, the inside edges of the cowl inlets were just touching the foam. The inside shapes of the inlets were then traced onto the foam with a sharpie. Final shaping of the foam could then be done using the traced shapes as a reference.

Fibreglass cloth was layed over the foam shapes followed by lots of filling and sanding to blend them into the plenum shape, resulting in the finished pattern. The final two-part mould was then taken from this pattern using tooling resin and chopped strand fibreglass mat.

The plenum itself was made using fibreglass twill cloth, core mat and fire retardant vinylester resin.

Those of you who are familiar with fibreglass work will know this is very much the 'Readers Digest' version. There is a lot more detail to the process than described here. I have the advantage of being general manager of a composite manufacturing company, (Composites International Ltd) mostly doing aviation related work, so have the advantage of resources and plenty of experienced help to call on for ideas if I need it.

Tahoe...? Lubbock...? I have to confess I had to google these places to find out where they were. Yep, they look really nice,....and quite a contrast to the temperatures we are currently experiencing in the middle of one of our hottest summers on record here in NZ!

If anyone wants more info I will do my best to help.

Clive
Reply With Quote
  #14  
Old 01-16-2011, 03:44 PM
Flaude Flaude is offline
 
Join Date: Sep 2010
Location: Paris
Posts: 14
Default

Absolutly beautiful but does it worth the hours!!
Reply With Quote
  #15  
Old 01-16-2011, 06:40 PM
whittfic's Avatar
whittfic whittfic is offline
 
Join Date: Apr 2007
Location: Auckland, New Zealand
Posts: 128
Default

Quote:
Originally Posted by Flaude View Post
Absolutly beautiful but does it worth the hours!!
Depends on your perspective I guess. If your primary interest is to get flying quickly then probably not. However I am one of those people who 'gets' to build the plane rather than 'has' to build, so for me it's not an issue. Besides it's taking me a while to save for a Skyview so I have time

Anyway, given my occupation, fibreglass work is not the scary beast that it can be for some, so it's each to their own I guess. Have a look at this website www.compositesinternational.co.nz in about two weeks time when we have it up and running and you will see what I mean.

In answer to an earlier question, won't have any temps or any other flight info for a while, I am still at that 90% done, 90% to go stage of construction.

Clive

Last edited by whittfic : 01-16-2011 at 06:46 PM. Reason: Added text.
Reply With Quote
  #16  
Old 01-18-2011, 03:44 PM
whittfic's Avatar
whittfic whittfic is offline
 
Join Date: Apr 2007
Location: Auckland, New Zealand
Posts: 128
Default

Quote:
Originally Posted by whittfic View Post
Have a look at this website www.compositesinternational.co.nz in about two weeks time when we have it up and running and you will see what I mean.

Clive
Website up and running now.

Enjoy.

Clive
Reply With Quote
Reply



Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

vB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Forum Jump


All times are GMT -6. The time now is 05:17 AM.


The VAFForums come to you courtesy Delta Romeo, LLC. By viewing and participating in them you agree to build your plane using standardized methods and practices and to fly it safely and in accordance with the laws governing the country you are located in.