Pieter Visser's X350

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Pieter001
Posts: 214
Joined: Wed Jul 03, 2013 7:03 pm
Closest Airfield: NZWN
Location: Wellington NZ

Re: Pieter Visser

Post by Pieter001 » Fri Mar 14, 2014 6:32 am

Last night I did not do the layup as I had thought... I did move my resin off the garage concrete floor. The container is still closed tight as the day I got it, but the resin felt syrup like when I shook it, so opted to let it rest. If only we had sunshine up here!! We have a lovely solarium next to our bathroom, which heats up plenty when the sun shines, but alas, only cloud. I'd love to leave the resin container in there for 2 days :)

Over the weekend I'll work with the resin and see how it goes. Got a new battery for my small scale, which ought to do the job.

What I did do was to test my bow cutter, which seemed to work just fine, but I'll need to give it a longer span for the wings. As I'm planning on doing the rudder and horizontal stab to start, it should be fine.
Attachments
20140313_194421.jpg
Bow cutter with Tooth Proof element (31kg)
20140313_194421.jpg (200.41 KiB) Viewed 2892 times
Last edited by Pieter001 on Sat Jan 27, 2018 12:54 pm, edited 1 time in total.

Pieter001
Posts: 214
Joined: Wed Jul 03, 2013 7:03 pm
Closest Airfield: NZWN
Location: Wellington NZ

Re: Pieter Visser

Post by Pieter001 » Fri Mar 14, 2014 6:38 am

For my element I used 31kg "tooth proof" which I found at our local angling shop after much effort spend in bigger towns :roll:

The heat source is actually an old Sansui HiFi transformer which delivers 13.6v and 5 amps. I used an old computer power supply and stripped out all the content, except for the 12v cooling fan, which I connected to the transformer output. Thus, once switched on, the fan cools the whole story and I simply connected a little 4 amp fuse in line on one of the output lines. At the end of each line I connected a little croc-clamp to connect to the element. After all the testing I found that I do not need to reduce the current at all and that the element seems to generate the perfect heat from the 13.6v / 5amp. Will see how this changes when I go to 1.1m length as I'm on about 90cm at the moment. The test cut was perfect, but my element can be a little tighter to be more accurate.
Attachments
20140313_194500.jpg
Element with the crock-clamp
20140313_194500.jpg (208.22 KiB) Viewed 2892 times

Pieter001
Posts: 214
Joined: Wed Jul 03, 2013 7:03 pm
Closest Airfield: NZWN
Location: Wellington NZ

Re: Pieter Visser

Post by Pieter001 » Mon Mar 17, 2014 11:09 am

This weekend I did not get much time to work on my kit as planned. Also, the one thing I did do, took longer than I had imagined.

I wanted to mark the engine mount brackets on the firewall so that I can start the support layups onto the firewall, but marking the holes proved quite challenging, as it was not as simple to get the centreline on the FW! After much measuring I decided to trust the top centreline and levelled the canopy sills, where after I used a deadweight on a line to determine the centre at the bottom. So finally got a line and then commenced the measurements, which is very close, I'd say 3mm out maybe on the left to right side, but close enough to get going I trust.

Did decide to buy the engine mount, so I can be 100% sure of the position of the holes. Tonight I'll start cutting my layups the rest of the week will measure and mark the landing gear cut outs etc. inside the fuselage.
Attachments
IMG-20140315-WA0001.jpg
IMG-20140315-WA0001.jpg (189.32 KiB) Viewed 2883 times
Last edited by Pieter001 on Mon Apr 07, 2014 3:39 pm, edited 1 time in total.

Pieter001
Posts: 214
Joined: Wed Jul 03, 2013 7:03 pm
Closest Airfield: NZWN
Location: Wellington NZ

Re: Pieter Visser

Post by Pieter001 » Thu Mar 20, 2014 8:58 am

Finally, last night started to measure and cut the fiber for the engine support layups.

I completely forgotten how this stuff makes you itch!! Still have to cut the unidirectional tonight :lol:

Also need to measure and mark the fuss on the inside for the gear cut outs etc.
Attachments
Glass cut for engine lower mount.jpg
Cutting glass for engine support
Glass cut for engine lower mount.jpg (28.42 KiB) Viewed 2867 times
Last edited by Pieter001 on Sat Jan 27, 2018 12:57 pm, edited 1 time in total.

Pieter001
Posts: 214
Joined: Wed Jul 03, 2013 7:03 pm
Closest Airfield: NZWN
Location: Wellington NZ

Re: Pieter Visser

Post by Pieter001 » Tue Mar 25, 2014 9:19 am

Over the past long weekend I did make some time to work on my build, but did not get nearly as much done as I had hoped. Suppose this is likely to happen often :(

I did however finish cutting the fiber for the lower engine mounts, which took a long time. The uni-directional is a pleasure to work with, but the 410gr is the itchy one!

I found the uni-directional 500gr was taped at the one end, so I applied the same logic and it works brilliantly to keep the fiber from fraying. I then tried the same on the 410gr and found it work well, not as good as the uni, but it certainly assists in the cutting and fraying.
Attachments
20140321_125022_small.jpg
Taped Unidirectional 500gr
20140321_125022_small.jpg (30.84 KiB) Viewed 2831 times
Last edited by Pieter001 on Sat Jan 27, 2018 1:01 pm, edited 1 time in total.

Pieter001
Posts: 214
Joined: Wed Jul 03, 2013 7:03 pm
Closest Airfield: NZWN
Location: Wellington NZ

Re: Pieter Visser

Post by Pieter001 » Tue Mar 25, 2014 9:31 am

I also set to work on the inside of the fus to prepare for the layups of the lower engine supports.

The instructions are to get the layup 130mm up on the FW and not the original 100mm. This is to support he rudder pedal mounts on the FW. It also states that one has to grind away the FW flange on the composite FW. This is to secure the bond and ensure that this critical component is as strong as it should be. The grinding is a little messy, but I suppose one should get used to this when working with composites. I started out using a milling bit in the drill, but this proved very slow and not easy to get a good finish, so I later used the small angle grinder and a general purpose diamond disc. Works much, much faster ;)

To get the main gear cut out positions, I transferred the centre line on the outside of the lower fus to the inside by drilling a couple of 1.5mm holes on the line. I then used a right angle to get the lines and angles of the main gear cut outs. It is IMPORTANT to work from the centre line and not the FW, as the FW could be installed at a thrust angle and therefore deliver inaccurate measurements.

If all goes well I'll do the layup on the lower mounts this weekend, but there also a bachelors to attend... :lol:

* * N O T E * *
Marking out the landing gear cut outs is quite task and one is always a little nervous about how accurate you are. When I turned my fuselage upside down to do the upper engine mounts, I found that my gear cut outs are actually marked clearly on the fuss :idea: !! So glad that I did not cut out my markings, which are pretty accurate, but 1/2 cm too far aft...
SO CHECK your fuss, you could save time and be accurate! Check the below pictures about this...
Attachments
20140425_163550.jpg
Marked GEAR cut out bottom of fuss 1
20140425_163550.jpg (171.21 KiB) Viewed 2662 times
20140323_165734_small.jpg
Left Lower FW flange ground away
20140323_165734_small.jpg (25.2 KiB) Viewed 2830 times
20140323_155258_small.jpg
Centre line and gear cutouts
20140323_155258_small.jpg (19.84 KiB) Viewed 2830 times
Last edited by Pieter001 on Wed May 07, 2014 5:40 pm, edited 2 times in total.

Pieter001
Posts: 214
Joined: Wed Jul 03, 2013 7:03 pm
Closest Airfield: NZWN
Location: Wellington NZ

Re: Pieter Visser

Post by Pieter001 » Mon Mar 31, 2014 8:26 am

On Sunday afternoon I set to work on my first layup. I was a little nervous, but charged the kitchen scale with a fresh battery and set to work. I used a stanley knife to cut the peel ply and after a bit of fiddling found it quite easy to remove. I then sanded the area with 40 grit and used a new brush and the vacuum cleaner to clean it properly.
I then took all my pre-cut glass fibre and lay it out in the sequence I was going to bond them. Using the kitchen scale and 100:33 ratio, I mixed a cup of resin and hardener. The area where I ground away the FW flange, is a little rough and uneven, so I thought it maybe good to put a little flox over that area. Thus poured around 100ml of resin into another cup and added some flox. I used very little flox as all I wanted was a smeer, not a build up. This flox mix I put over the flange area sparingly, but I made sure it filled all the dips and uneven areas. Using a 100mm brush I then coated the entire area to be glassed once with a layer of resin and then stared the layup.
Started with a 410gr and alternating with the 500gr unidirectional, 5 layers of each. I worked slowly and made sure that there were no air pockets trapped anywhere in the layup. I also mixed only about 200gr in the paper cups at a time and I used a new cup for each mix, leaving the empty cup for later evaluation of the content.
After I finished all the 1130mm layups, which was 4 hrs later, I decided to call it a day and get some supper. I peel ply-ed the entire area and asked my son to assist me with lifting the fuss of the floor and onto a stand I had made earlier. The stand is positioned under the FW and this is to ensure that the fuss is not ill aligned during the curing process!
All in all I found the layups to be easier than I had expected. I was also relieved to see that all the empty cups had cured beautifully overnight and the actual layup in the fuss seems to be pretty hard too. By this afternoon it should be rock solid, but I'll leave it for another 24 hrs before I put it back on the floor and continue the layups of the 780mm sections.
Attachments
20140330_200954_small.jpg
Another view of 1130mm layup
20140330_200954_small.jpg (22.73 KiB) Viewed 2797 times
20140330_200913_small.jpg
1130mm layup peel plyed
20140330_200913_small.jpg (20.68 KiB) Viewed 2799 times
Last edited by Pieter001 on Sat Jan 27, 2018 1:05 pm, edited 1 time in total.

Pieter001
Posts: 214
Joined: Wed Jul 03, 2013 7:03 pm
Closest Airfield: NZWN
Location: Wellington NZ

Re: Pieter Visser

Post by Pieter001 » Mon Apr 07, 2014 9:05 am

Seems Sunday afternoon is my work slot at present.

I completed the left lower engine mount layups and it came out well, I'm happy with the work. Did experience a little frustration yesterday when my digital scale packed up and would not read accurately at all!! I then used the mechanical kitchen scale, which is obviously not very accurate, but it was all I had and it had to make do. I did notice that 2 of my mixes in the cups were still not rock hard... I do believe that they will however harden correctly by this evening, but will keep a eye on it. So this afternoon I'm going hunting for another digital scale ;)
Attachments
20140406_204010 - Copy.jpg
780mm Lower left layup 2
20140406_204010 - Copy.jpg (23.29 KiB) Viewed 2779 times
20140406_203849 - Copy.jpg
780mm Lower left layup 1
20140406_203849 - Copy.jpg (216.4 KiB) Viewed 2779 times

whisper
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Re: Pieter Visser

Post by whisper » Thu Apr 10, 2014 8:48 pm

Its hard to see in the pics but I assume you did remove the peelply first?

Pieter001
Posts: 214
Joined: Wed Jul 03, 2013 7:03 pm
Closest Airfield: NZWN
Location: Wellington NZ

Re: Pieter Visser

Post by Pieter001 » Fri Apr 11, 2014 12:37 pm

Jip, I did. Cut and removed with a Stanley knife and also sanded the area before I started the layup. On the FW flange area, where I had used the angle grinder, there was no more peel ply to remove, so that area was only sanded.

I believe I got a good bond for the engine layups. The 20 layers bonded there are quite thick and I'll have to cut a little into this for the gear cut out and I'll certainly have to grind the gear humps a little to make them not ride up on the layup.

This weekend I hope to start and complete the lower right engine mount :)

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