Re: Carbon (Kevlar) Prop Outlines

From: <mkirda_at_sbcglobal.net>
Date: Thu, 20 Dec 2012 02:29:42 -0000

Here is how I would reverse engineer it:

Find appropriate prop block. Print outline onto paper in the size I want, making sure it will fit onto prop block.

Cut outline out nearly to the line. You want to be able to see the line.

Cover prop block with some plastic.

Lay out several squares of fiberglass a bit larger than the outline. I'd try 2oz cloth first. I am unsure of the number of layers needed, probably try for 10 pieces to start.

Lay one out and stipple in laminating epoxy (i.e. EZ-Lam) with a brush. Add layers until you reach 4. Sop up any excess. Add layer of plastic or mylar.

Add layer and epoxy again as above. Lay paper outline form in place. Add next layer and epoxy. Sop excess and add another layer of plastic or mylar.

Follow by four more layers with epoxy. Sop excess.
Cover peel ply and paper towel layers.

Put into vacuum bag and bring it down as appropriate.
Let sit 24-48 hours, post-cure as necessary.

Personally I'd drill holes into the block at this point before separation. Easiest now and easy to fill the holes on the prop block.

Pull layers apart. Use vacuum hose and sander to bring the center layer down to the line.

Screw the layers together. Sand again to within a reasonable tolerance of the line.

Wax edges and channel well before using with UHM carbon or kevlar tow.

The key questions are whether four layers of 2OZ cloth are enough or if one should go with thicker cloth/more layers. Some experimentation is necessary here.

Regards.
Mike Kirda

--- In Indoor_Construction_at_yahoogroups.com, "lauren.rezac" <lauren.rezac@...> wrote:
>
> Were the construction forms molded on a prop pitch block?
>
Received on Wed Dec 19 2012 - 18:29:44 CET