bracesport DLG

[Wildthing]

I am making a start on the fuse - step one is wrapping the fuse/boom with cling film as the release surface and adding some 3K tow for bending strength - I added a fillet between the fuse and the boom to smooth out the transition.

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I have to ask, do you play pool ?

 

[bracesport]

@Wildthing - not any more... !!

 

[bracesport]

I have placed the braided sleeves ready for some epoxy, but decided to use some biaxial cloth under the fuse braid for the double thickness - the plan will be to wet out the cloth in the fuse with the boom braid pulled back - once that is done I will wet out the boom braid and then sleeve over the fuse braid - wrap and add the outer moulds to shape the fuse area.

 

[bracesport]

On with the epoxy!

First layer of the fuse and the raw boom was wet out and then the boom braid placed, wet out, and wrapped - the second layer of fuse braid was added next, wet out, and wrapped from the rear just short of the front wing tip lip - then I worked the braid into the lip area with a popsicle stick followed by wrapping with the cling film - with all that done I added the outer moulds and did a second wrap of the boom.

Now we wait!

 

[bracesport]

De-moulding - No moulds were harmed in this process!

the outer moulds all popped off easily - where I had split outer moulds the surface is very good compared to the tapered end cap without clamping (I will make a new split mould for that section) - the internal moulds worked a treat and also released easily - the outer surfaces do need some cleaning up as my cling film shows the winding lines - this is to be expected - 42g is not too bad!

I have an idea to mould in the wing mount nuts (something to try), so I will make another fuse with the knowledge gained here!

 

[bracesport]

I have made some more moulds in CAD to do two things.

(1) improve the fuse moulding quality by using outer male moulds over all sections.
(2) to allow me to try moulding directly into the outer moulds using a ballon to compress the carbon fibre.

I will do some more trials next week - the first version from this week is not too bad, and is nice and stiff, bu I wonder if I can make the boom lighter given the braided CF sleeve are 3k (quite heavy) - I will try and roll some of my carbon cloth as an experiment!

 

[Wildthing]

Pretty slick

 

[bracesport]

first batch of fuse mould prints went well - 20hrs!

 

[bracesport]

Yay I found some blue foam - 2400 x600 x50

I am also starting on my templates for the sine wave formers.

 

[bracesport]

I finished all my moulds - here are the nose cover moulds

 

[jonoashton]

Hey Phill
This is looking awesome
I use a long balloon when I make my scratcho fuse and it took some time to get the process right but now it works well. Too much to type out on my phone but call me some time and I will tell you about my early failures so as you don’t do the same
Jono

 

[jonoashton]

Blue foam is the best. Very slightly heavier but WAY stronger and easy to sand

 

[bracesport]

@jonoashton - I am not at work today, but I hear my foam has arrived (yay) - I will do some prep cutting the blocks next week , but I am keen to get a good fuse done before I focus on the wing - I think I will go for the female moulds with a balloon as this will give me a good finish (more like production ships) - I will give you a call!

Oh, we still have to maiden the pitcheron!!

 

[BATTLEAXE]

Man you do some quality work. I am jealous of the plethora of skills you have at hand to accomplish these rigs. Hats off to you sir. I will be watching for sure

 

[bracesport]

@BATTLEAXE - thanks, well you know how addictive the building gig can be! I seem to be drawn to the composites these days - I am looking forward to moulding some fuse parts this week - I found a couple more pool cues so I will probably end up making a couple with different boom characteristics.

 

[bracesport]

Some tests with a balloon - the system is there but I need to ensure it can hold pressure.

 

[bracesport]

I have added the first coat of PVA mould release - I watched a video where they were moulding directly into 3D printed moulds using only the PVA release material (no wax) - we shall see won't we!

 

[bracesport]

I used paper to make some basic templates for the glass and carbon fibre layups - one side of each mould has a salvage to lap over and join the halves.

 

[Wildthing]

Some tests with a balloon - the system is there but I need to ensure it can hold pressure.

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Where do you come up with this stuff?

 

[chrisvdv]

Where do you come up with this stuff?

Manufacturing of carbon bicycle frames.