Custom canopy prototype mold

[Buzzkill]

In my eternal tinkering and boredom, not to mention my conversations with fellow canopy horders and post in this forum, I am attempting to make a custom canopy from scratch for the Gaui 200.

So far I've fashioned a "mold" if I may call it that that resembels my favorite canopy the Trex 600N. No it's not just like it (hey It's me) but I do like the shape.

Problem is I've never worked with fiberglass before. The mold or plug is made of natural molding clay that air drys. I need a way to get the FG off the thing after I lay down the resin and the cloth.

Anyone know of a product that I can apply to the clay so the fiberglass won't stick?

The plug will have to be sanded after it drys and all that but it has been fun playing with it.

[rotorhead58d]

http://www.fibreglast.com/?GCID=S18576x039&KEYWORD=molds+of+fiberglass

there is a newb section on this thread buzz. make one for me.

[Buzzkill]

Cool thanks man, I'll give it a read.

[rotorhead58d]

el gusto es mio

[cb3d]

Hey Buzz, I may be interested in one of these. You may have found a way to support your addiction here.

[Buzzkill]

I'm hoping so. Untimately I got on this canopy kick because I don't like the shape of my Trex 500 canopys. I have 4 of them but would kill for a 600N shaped 500 canopy.

[rotorhead58d]

I'm hoping so. Untimately I got on this canopy kick because I don't like the shape of my Trex 500 canopys. I have 4 of them but would kill for a 600N shaped 500 canopy.


for some reason, the industry isn't keeping up with our needs... it has improved greatly in the last few months, but canopy choices and cf blades would be sweet. i can't believe no one has cashed in on this yet???

[Buzzkill]

There's a few people that are going to make canopys for themselves I think. I sure hope someone with more skills than myself comes up with a good solution. If this one works I'll distribute them around.

[rotorhead58d]

http://www.helihobby.com/html/esky_fixed_pitch.html

buzz...would it be worth the money to try these? they are one inch longer

[Buzzkill]

http://www.helihobby.com/html/esky_fixed_pitch.html

buzz...would it be worth the money to try these? they are one inch longer

Interesting. I really don't know. I'm not sure the root would fit in the grips. Would be nice to know without spending the $$.

[rotorhead58d]

it would be nice if there were more specifics on parts in general. like measurements, and clearances.

[Buzzkill]

Looks like I'll have to figure out how to do a female mold. The male mold isn't working that great.

[rotorhead58d]

Looks like I'll have to figure out how to do a female mold. The male mold isn't working that great.

buzz, can you use a 450 canopy, and fill it with clay? just a thought

[Buzzkill]

Probably, at least for a 450 size canopy.

I have made one (Gaui 200 sized) so far. Still needs a lot of sanding. I'm thinking of using it as a plug and molding clay around it, let it harden and use them together, Male mold works ok just have to power sand the finish which is a pain in the butt.

Still hopeful. The one I've got will be the plug. I'd sure like to paint it though :thumbup:

I'll post some pics soon of the results. I may even see if I can find gelcoat localy. I'm pretty excited about this. If anything, I'll have custom canopys that don't cost $17.

[Gr4yb3ard]

I saw a video long ago on how they made boat parts.

They made a male plug, and finished very carefully, put release agent on it, then basically stuck it in a tub of some kind of permanent material, not sure what.

After pulling the male plug out, this female mold then got coated with release agent, gelcoat was sprayed inside, after which came chopped fiberglass. The finished product was extremely well finished and dimensionally stable. The mold was apparently good until someone broke it, or they changed models.

Maybe some kind of resin to make the female mold? Next problem is how to get hold of a sprayer or technique to handle chopped fiberglass, that don't sound cheap (or non-messy).

But after that, you could pull canopies till the cows came home ;-)

Gr4yboard
"...<REAL> boats are made 'o wood..."

[Buzzkill]

I've seen them do tub surrounds in a similar fashion on Discovery channel. So far I've got about $20 in materials a one canopy. I think I'll try the clay thing first for the female mold. FG doesn't stick to it. Not sure what type of finish it would produce but, if I can locate gelcoat localy I think that will work.

What I should have done was made a vacumn mold. That would have worked perfect. I think a single piece (no seem) canopy would be possible with a vacumn mold with some trimming.

I've seen several "homemade" vacumn molds on youtube so that part shouldn't be too hard to do. Since I'm a dreamer I'm scheming some scale fuses. I just hate the two part plastic stuff but don't see a way around it with my limited skills. My GF is pissed, I've been back and forth to the garage, hold this one canopy turning it in my hands, sanding and daydreaming.

I don't think Darth has anything to worry about but dang something so simple has been so much fun. Who'd da thunk?

[Buzzkill]

For anyone interested, here's a link I found in the Trex 500 forum. It's translated from French but is still a great source of info. http://www.google.com/translate?u=http%3A%2F%2Fforum.modelisme.com%2Ft13 8373-comment-faire-une-bulle-dhelicoptere.html&langpair=fr%7Cen&hl=fr&ie=UTF8

[Gr4yb3ard]

Vacumn forming would be okay, in fact it's starting to look lots better after I considered all the hassle with FG.

One trick that we used to use to replace canopies:

Male mold, usually wood covered with plaster of paris, waxed, sometimes covered with some type of cheesecloth. I don't know what type of fabric this was, sorta sounds weird, but I will try to look it up.

Then a frame was constructed using four vertical pipes supporting about a 3x6 bank of heat lamps. Below this movable frame, connected to the pipes with sliding I-rings, that clamped a piece of plexiglass or lexan.

The plastic was moved up, heated until it sagged well, then quickly slid down over the mould and a bit past it.

Amazing results. At our scale this might be simpler..

Gr4yb3ard
"...scholar of worthless information..."

[Sirwallis]

buzz i would definitely give the vacuum molding a try, thats what i am using on mine and its turning out to be a breeze, so far my cost for the vacuum table materials is $5, i already have a shop vac to use so that certainly helped. the plastic im useing is lexan it was $4 for three 11"x14" sheets which is a little steep but still not bad.

i personally like it because you dont have to be concerned with texture, every thing comes out smooth any way, you can use models or even other canopies as your "mold", you can reheat and continue to shape, and plastic is cheap, you can find really good deals online and you can even use plastic packaging if you find a big enough peace.

now i know that this doesnt put plastic canopys in the same league as FG, but for what your doing i highly recommend it.

[Buzzkill]

Do you have any done? I'd love to see someone else's work. The FG is really time consuming but has been a joy to do.

[Sirwallis]

not quite, i have one clay model and the table ready to go, i wanted to build another model be for i got started but ive been really busy, i think I'm just going to go for it tomorrow so that i know what to do/ not to do on the next clay models

[Buzzkill]

I fitted the prototype tonight. Had to do some rough cutting but got it on. I painted the clay mold and inked some sketches on it that the FG picked up so it looks like hell but I'll post some shots. Look's like I'll have to make another mold. Maybe I'll actualy measure some things this time. Should look tons better after some paint and clear coat.

[rotorhead58d]

not too shabby buzz.

[Buzzkill]

Thanks man. It's a first attempt. I think I'll follow Sirwallis and do the vacumn form thing after making a new mold.

[rotorhead58d]

make me one that looks like my avatar. i'll give ya a dollar...