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THIS PAGE WILL SHOW THE PLUG, THE MOLD, AND DETAILS ABOUT
THE RAD FUSELAGE'S CONSTRUCTION

 

THE PLUG STARTS WITH A  BLOCK OF BASS WOOD 2.5 INCHES BY 2.5 INCHES SQUARE. A FULL SIZE PAPER DRAWING FROM THE DRAFTING TABLE OF THE PROFILE SIDE AND TOP ARE CUT ON BAND SAW. THE WING SADDLE IS GENERATED IN A AIRFOIL PROGRAM TO PROVIDE BEST MATCH OF TOP LOADING WING. SD7080 MODIFIED. NEXT THE SQUARE CORNERS ARE SANDED TO MATCH THE DESIGNERS EYE BALLING OF THE FUSELAGE IN MIND.  THE VERTICAL STABILIZER IS CUT IN BLUE FOAM USING A SYMMETRICAL AIR FOIL AND OBEACHI COVERED, AND HARDEN WITH RESIN AND GLASS POWDER FILLER. THE VERTICAL STABILIZER IS GLUED ON AND THE ENTIRE STRUCTURE IS PRIMED WITH EPOXY PRIMER. SANDED WITH STEP DOWN GRIT SAND PAPER FROM 180 TO 1,500, RUBBED WITH POLISHING COMPOUND, THEN POLISHED WITH MOLD RELEASE WAX.

A FIBERGLASS IS THEN PLACED WHERE THE CANOPY AND WING SADDLE ARE TO FORM A MOLD SMOOTH MOLD FOR EACH. 

THE CANOPY IS MADE FROM THE MOLD TO PROVIDE AN EXACT OUT LINE

 

A CANOPY RECESS IS CUT BY OUTLINING THE SHAPE AND ROUTING THE DEPTH. SANDING AND SHAPING THE CUT OUT FOR THE CANOPY FIT. THE CANOPY RECESS IS THEN COATED WITH RISEN, PRIMER, AND SANDED AND POLISHED AS TO CREATE
THE FINAL PLUG.

THE PLUG IS LADED ON TOP OF A SPLITTER PLATE AND A PROFILE LINE IS DRAWN AND
USING A SABER SAW A HOLE OUTLINE THE PLUGS PROFILE IS CUT.

 

THE PLUG IS FITTED INTO THE PROFILE CUT, AND THE GAPS ARE FILLED WITH MOLDING CLAY. HOWEVER, AUTO GAP FILLER CAN BE USE. THE TRICK IS MAKE FLAT PLAN ON THE FILLER PLATE TO THE PLUG.

USING A SQUARE BLOCK OF NYLON PROVES TO SHAPE THE PLUG TO PLATE. 

ONCE THE GAPS ARE FILLED AND SQUARED, THE PLUG AND FILLER PLATE SURFACE IS POLISHED WITH MOLD RELEASE WAX, AND COATED WITH MOLD RELEASE AGENT.
THE NEXT STEP, USING FINE FIBERGLASS CLOTH AND RESIN COVER THE PLUG. INCREASING THE WEIGHT OF THE FIBERGLASS AS YOU BUILD UP LAYER AFTER LAYER OF FIBERGLASS. 

ONCE THE FIBERGLASS HAS CURED IT IS REMOVED FROM THE SPLITTER PLATE AND TURNED OVER. THE FIRST HALF IS CLEANED OF SNAGS AND PREPARED WITH WAX AND MOLD RELEASE TO MAKE THE SECOND HALF OF THE MOLD. 

THE TWO HALVES ARE DRILLED WITH ALIENING HOLES AND EXCESS FIBERGLASS IS CUT AND SMOOTHED. THE INTERIOR IS NOW POLISHED ONCE AGAIN, AND WAXED.
IT IS NOW A MOLD FOR MAKE MORE RADS.

A NEW FUSELAGE IS BORN FROM THE MOLD. NOTICE THE DOWEL ROD ARE GLUED
TO CREATE A FULL LENGTH SUPPORT FOR THE TASK OF RESIN AND FIBERGLASS.

FRESH OUT OF THE MOLD. CARBON FIBER IS USED TO REINFORCE CRITICAL LOCATIONS IN THE TAIL AND ALONG THE FUSELAGE TO PROVIDE STRENGTH AND LIGHT WEIGHT BUILDING.

 

8.288 OUNCES AFTER SLAG IS REMOVED AND BASIC TRIMMINGS.

KEEP CHECKING BACK AS MORE PICTURES WILL BE ADDED WEEKLY

 

BUILD PAGE

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