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SH-50 Fuselage Construction Posted by Greg Smith on Feb 2, 2003, 22:05 Fuse This will be a 2-part fuse. The front half will be Kevlar and Epoxy, laid up over a male mold, which extends just past the wing. The tail boom will be made with Kevlar and Epoxy using a cone of Mylar as a former. The 2 will be mated after they are released from their respective molds. The Plug The first 2 pix are of the fuse plug after most of the shaping has been done. This started as a 2 x 2 square 18 inch piece of basswood. An outline of the fuse was drawn on the side and top. It was then cut to rough size on a band saw. A bit more roughing was done on a belt sander. The majority of the shaping was done with a hand plane, a couple of files and sand paper. These two pictures show a mock-up of the fuse. A cone of drafting paper is simulating the boom. We wanted to stay away from the thin carbon boom mostly for asthetics. This jig was made so we can rotate the fuse while working with the plug. Before we can layup the kevlar on the mold we prepared the plug with a coating of epoxy and filler, sanded it to final shape and applied several coats of wax so it will release when we are done. Applying the epoxy to the plug. Here we made a pattern for cutting out the kevlar. The cut kevlar. We use a single layer of 4oz and a second over the wing saddle. Wetting out the kevlar and forming it to the shape of the plug. Here is the cone of mylar we will form the tail boom on. It has been coated with wax so, hopefully we can use it again. The boom has 2 wraps of 1.75oz kevlar wrapped around the mylar. The finished boom. Other Components Wing Final Assembly Print this article - Email this article ---------- ---------- ---------- ---------- ---------- ---------- ---------- ---------- ---------- ---------- ---------- ---------- ---------- ---------- ----------

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