SFS 31 Milan

Post by **Noël Rumers** » 29 Sep 2017, 23:56

Cliff, sorry about the smile...couldn't help it

after all the work that goes into the mould etc...
And no it is not my own design, the vacuum machine. I have seen a smaller version in a model shop once.
At that time, my 1/2 scaled Moni had a very big canopy and much bigger than the 600 mm machine in the shop. So I was able to look into this machine and redesigned it and had it made a bit bigger as a school project that I sponsored...
A local company wanted to charge me a lot of money to pull a plug for me...
Now I have my own 950x550 mm big and in height about +220 mm.

More building on the Milan now...
The rudder was build up like Cliff Charlesworth did, with a pin and a plywood tongue. One screw will hold the rudder in place, easy in transport.
And know that the real rudder could be taken off as well.
The rudder control arm is made and also the tail wheel control arm. I used epoxy plate for this. These will be glued in after covering with fabric.

Noël

Post by **Noël Rumers** » 30 Sep 2017, 00:09

...the elevator is also installed and that was not so easy.
I used Alu L-shaped profiles. After not lining up properly I glued them on first after drilling new hold and that did the trick.
When the glue was set, a smaller hole was drilled to put the screws in. Easy enough afterwards.
With the L-shaped hook on piece in place the elevator hooks where glued in with 5 min epoxy.
A ply strip was cut to hold the elevator in the right position while the hooks where glued in.
One screw will hold the elevator in place.
Noël

Post by **Noël Rumers** » 30 Sep 2017, 00:30

...and then the most difficult of all: "The Cowl".
The mould was ready now, and to make the top and bottom moulds, not that simple...
The spinner line was also not the dividing line on the two sides.
See the drawing. The height difference was 8 mm.
A piece was made that fitted around the cowl outlines like a glove.
The very small gap was sealed off with TEC 7, have it set and then cut of so a very nice gap free support was made. Due to the waxed plug, the TEX 7 will not stick hard to the plug and can be taken off easy.
All was again waxed so it will come of easy.
Sorted in the end and now the bottom part was made first.
The top part will be for tomorrow.
Noël

Post by **Noël Rumers** » 03 Oct 2017, 01:16

...the bottom part was ready and hardened out. Now the support part could be removed, but carefully, not to push the bottom mould of...
This was done in steps. All went well and the edge, containing the TEC 7 gap filler could be removed and waxed as well.
With that done the top part was made the same way.
First the gel coat was put on to have it set a bit, next the glass with epoxy.
This morning the parts could be taken of the plug...
All was very easy and later the plug was unscrewed from the front fuselage.
A gentle push and it was of as well.
I did cut the plug to the right size and put it back in both the bottom and top part to mark the cutting line once the real parts are made.
Later I grinded the edges down so all was a bit safer to handle.
Now both mould must be cleaned and waxed to start making the cowl that goes on the fuselage.
Noël

Post by **Noël Rumers** » 03 Oct 2017, 01:19

...and more...

Post by **Noël Rumers** » 03 Oct 2017, 01:25

...also the covering of the turtle back is started. Due to the little bend in the top line, this had to be done in two parts.
The first part is one and the second part is ready to be glued in place.
I made paper design first before cutting the 0.6 mm ply.
Noël

Post by **Peter Balcombe** » 03 Oct 2017, 09:45

Wonderful as always Noël

Post by **Noël Rumers** » 11 Oct 2017, 01:15

Thanks Peter!
Here is a bit more...progress is slower than hoped for...
The rudder is sorted now and ready to cover.
I added a small wedge to have it fixed even better.

Noël

Post by **Noël Rumers** » 11 Oct 2017, 01:19

Also the elevator is sorted now and got the LE and tip blocks sanded to shape.
All ready to cover.
The turtle back of the fuselage is finished too.
Now the controls and cables must be build in before closing up the fuselage sides.
Noël