Help! FT Repair / Rihnoplasty

[Gr8folded]

After a successful 1st build and 99% successful maiden that ended after 6 minutes with a signal loss, I am repairing the entire nose of my plane up to the leading edge. FT rhinoplasty I guess...

Here is what I did so far and would appreciate any feedback as to the techniques I used in terms of a more efficient or effective way.

From the plans, I cut out the full nose section up to the leading edge in DTFB foam.

I then used a level to draw perpendicular line straight up from the same reference point off the leading edge, to cut off the nose as even as possible.

I then used small pieces of popsicle sticks, glued to the inside of the original fuse to provide guides and reinforcement when attaching the new nose. A few popsicle sticks were put in opposition on the new nose piece and original fuse to ensure alignment.

I've then glued the new nose to the original fuse.
Is the a better way to ensure the new section matches/meshes well with the original section? My concern was not to accidentally add any up, down or side angles.
As this was my first build, it was a bit of a challenge to cram all the wires into the power pod. As a solution I cut an access hatch in the fuse through the canopy and turtle deck. I then cut a hole fore and aft to pull the control surface wires, and the throttle wire up on on top of the main fuse deck.

As I am still unsure as to what caused my loss of signal, I then created two antenna exit points out of the canopy to ensure my antennas were at a 90° angle.

I have still yet to finish the turtle deck and the new power pod, but hopefully this will work.

Being my first, build of a powered plane, the silver lining to a crash is being able to come up with improvements such as the receiver access hatch. That said, if there is any major issue with what I've done by moving the receiver up above the power pod, please let me know.

Thanks for everyone's help thus far!

 

[Foamforce]

I haven’t done an entire nose replacement yet, but I’ve done a lot of other repairs. The technique I like to use is to remove 3/16” of foam from the joining edge of the replacement part, then just butt the new part to the old part and glue, similar to an A or B fold.

In order to get a perfect fit, use the new part or template to make the cut on the part that you’re repairing. For the nose, you could print out the whole nose template. Then cut the new parts from foam and remove the 3/16” of foam at the edge. Before you glue the new nose together, place the new pieces over the old pieces that you’re going to replace and scribe a line on the original part, sliding your knife along the edge of the new foam while scribing that line onto the original. Then finish cutting it. If you do it this way, then your cut will be a perfect fit.

 

[skymaster]

After a successful 1st build and 99% successful maiden that ended after 6 minutes with a signal loss, I am repairing the entire nose of my plane up to the leading edge. FT rhinoplasty I guess...

Here is what I did so far and would appreciate any feedback as to the techniques I used in terms of a more efficient or effective way.

From the plans, I cut out the full nose section up to the leading edge in DTFB foam.

I then used a level to draw perpendicular line straight up from the same reference point off the leading edge, to cut off the nose as even as possible.

I then used small pieces of popsicle sticks, glued to the inside of the original fuse to provide guides and reinforcement when attaching the new nose. A few popsicle sticks were put in opposition on the new nose piece and original fuse to ensure alignment.

I've then glued the new nose to the original fuse.
Is the a better way to ensure the new section matches/meshes well with the original section? My concern was not to accidentally add any up, down or side angles.
As this was my first build, it was a bit of a challenge to cram all the wires into the power pod. As a solution I cut an access hatch in the fuse through the canopy and turtle deck. I then cut a hole fore and aft to pull the control surface wires, and the throttle wire up on on top of the main fuse deck.

As I am still unsure as to what caused my loss of signal, I then created two antenna exit points out of the canopy to ensure my antennas were at a 90° angle.

I have still yet to finish the turtle deck and the new power pod, but hopefully this will work.

Being my first, build of a powered plane, the silver lining to a crash is being able to come up with improvements such as the receiver access hatch. That said, if there is any major issue with what I've done by moving the receiver up above the power pod, please let me know.

Thanks for everyone's help thus far!

is that duc tape on the nose

 

[Gr8folded]

I haven’t done an entire nose replacement yet, but I’ve done a lot of other repairs. The technique I like to use is to remove 3/16” of foam from the joining edge of the replacement part, then just butt the new part to the old part and glue, similar to an A or B fold.

In order to get a perfect fit, use the new part or template to make the cut on the part that you’re repairing. For the nose, you could print out the whole nose template. Then cut the new parts from foam and remove the 3/16” of foam at the edge. Before you glue the new nose together, place the new pieces over the old pieces that you’re going to replace and scribe a line on the original part, sliding your knife along the edge of the new foam while scribing that line onto the original. Then finish cutting it. If you do it this way, then your cut will be a perfect fit.

Great advice foam force. Definitely working smarter and not harder with that technique. Appreciate it!

 

[Gr8folded]

is that duc tape on the nose

Yes, it is duct tape. I found some very lightweight/cheap duct tape that barely added any weight to the nose, but reinforced and waterproofed the poster board turtle deck.

 

[Gr8folded]

Essentially the finished product. Just need to rebind the correct way and recalibrate the control surfaces.

 

[Merv]

Great looking repair.
On occasion I have needed to lengthen the nose of a plane to get the CG right. Used a similar process, just added an inch or two of foam & glued the original back on with the extension.