Fuselage Plug Construction

[CitationX]

I apologize if this has been asked previously or in another forum. I would imagine that most of the fuselages start off as a plug usually constructed out of foam based off of scaled down cross-section templates of the full size machine. The plug is then used to produce the necessary mold(s) for the various fuselage components then the actual fuselage is laid up using fiberglass and carbon fiber where necessary.

This all sounds fantastic yet quite an undertaking for someone with zero experience in this area of model building. I was wanting to know if anyone can recommend a good point of contact or even a website(s) that contains some really good documentation of this process? Dr. Tim seems to be a great resource on this subject I have heard.

I had the great fortune of visiting the Bell Helicopter plant in Canada last week and saw the production lines for the 206, 206L4, 407, 412, 430, 427. Most if not all of these full size machines have their R/C counterparts made by various manufacturers (Vario, Funky, Century, etc.).

I have 2 MA Fury machines that I would like to outfit at least 1 with a fuselage someday. I have heard that the Fury main frames are unusually tall for most fuses (uncomfirmed). I would really like to install 1 of my Fury mechanics in a Bell 407 fuse but I have yet to find a true 80-90 size 407 on the market. That is what lead me to think about constructing a 407 myself. I have the necessary cross-sections and documentation that I believe would be required. I just have no idea how to get started!!!

I remember seeing some photos of a stretched Long Ranger by a guy on the West Coast that he made to look like a 407 in Petroleum Helicopter paint scheme. It looked really nice but I wasn't sure how close it came to resembling a true 407. Much better than anything I have at least!!!

Anyway, just searching for information at this point. I appreciate any help I can get on this subject.

Thanks

[Heli_jack]

Big chunk there. To make your own plug is an extremely intense time consuming job. Making a mold from that is even more so. Tap Plastics has a thread somewhere that gives the basics, and someone has a published paperback that hobby stores sell. They will give you the idea. I would plan on making at least 3 plugs before you get it right and in a condition ready to mold, and probably 2, maybe 3 molds before you get the hang of that too. Principal is simple, actually producing one is another story.

It will cost you more to make the plug and mold than it would to get a different set of mechanics. Hopefully something with less moving parts like Vario and Graupner type mechanics. Inside a fuse you will want that.

I am not trying to burst your bubble, instead to save you some money and time so you can spend more time having fun and not cussing. :arggg:

[CitationX]

You make some very good points. All of which I have definitely considered. This will likely end up in the "pipe dream" category for me as do most of my projects. I am going to continue doing some more research just to get a better idea of the overall process. If you happen to come across the paperback you mentioned I would appreciate hearing more.

Thanks for responding by the way.