48″ Convair 240 – Wing Lofting

LoftedWings

  Pecking away at the Convair 240 radio control model.  This is being done for a contest on the Ezone forums, and so I really need to get moving on this thing to get it in the air by June 30th contest end date.  The wings are getting there – mostly lofted, just have to … Continue reading

Using Rare Earth Magnets to Join Composite Structures

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You know what I think is a little silly?  Using clecoes to join composite structures.  I mean, sure, they work, but unlike when you are working with sheet metal, at the end of it you have a bunch of useless holes that have to get filled in.  Also, multiple insertions/removals of the cleco tends to … Continue reading

The Method Part II – Demolding the Parts

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Following up on my previous post on my method of making high quality, re-usable tooling with CNC machined foam and Stretchelon bagging film, here’s how things tend to go on the demold side.  First, turn off the pumps, and then remove all the secondary fabrics/films that are bagging the part: I’ve left the peel ply … Continue reading

Creating High Quality, Reusable Molds with CNC Machined Foam and Stretchelon Bagging Film – aka “The Method”

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This post is really the culmination of a few years of research, research that I’ve decided to set loose into the world.  We call this “The Method,” or sometimes “The Stretchelon Trick” and it’s my primary method of creating tooling for composite parts these days.  As  an example, I’m using the Giles 200 gear leg … Continue reading

VariEze N388DT – Fuselage Refinishing

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I’m back from vacation!  Had a very nice time, but I’m happy to be back in the States, and working away on some cool projects.  James has been working on scraping all the old paint and fill off of the VariEze.  The paint is Imron, which has been holding up quite nicely, but the fill … Continue reading

Fun with MAXshot/EXAscan – Digitizing “The Racer” Fuselage

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Last week we were up in Reno, doing among other things, a digitization of a plane that is simply called “The Racer.”  The Racer is an as of yet unfinished Unlimited Reno racer.  It’s pretty much the smallest plane you can build around a Wright R-3350, which is still a pretty big plane.  The Racer … Continue reading

T-Splines Tip – Panel Line Breaks

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I figured I would do a quick little step by step on making panel line breaks with T-Splines.  The first thing is to make sure that you have an isocurve, or isocurve loop that follows the panel line break that you want.  This sometimes can be tricky – in the case of this windshield, I … Continue reading

Virtual Plastic – Porsche 962C – Main Body Complete

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Franky, even I’m surprised with how well this is going.  The basic  body is done, and now it’s time to sub-divide the whole thing and start adding details.  I was able to use tsBevel to create panel line breaks for the side windows, and a slight joggle for the windshield.  This really shows me that … Continue reading

Virtual Plastic – Porsche 962C – Start of Surface Modeling

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Continuing my little Tamiya Porsche 962C “virtual plastic” build, I spent a little time at the end of Friday working on the surface modeling.  I started (Basil this is for you!) by projecting a line onto the front fender.   Project is one of those handful of Rhino commands that works on stl meshes.  There’s not … Continue reading

Giles G-200 Progress – Intersection Fairings

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Moving along nicely now with the Giles G-200.  I realized that before I put any more time into the cowling, I needed to have all the rest of the intersection fairings finished up.  Really, the most complicated part, topologically speaking, is the intersection fairings.  Since the topology of the fairings must flow into the cowl, … Continue reading

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