Scratch building 1/4 scale Bell 206B, 206L and 407 fuselages

Rotor George · 03-22-2009, 01:15 PM

Last June I started scratch building three 1/4 scale fiberglass R/C helicopter fuselages. A Bell 206B Jet Ranger, a Bell 206L Longranger and a Bell 407. I wanted to make these for myself with the idea of having highly detailed parts complete with rivets right out of the molds.

It all started with a cardboard structure cut and hot glued together.

Rotor George · 03-22-2009, 01:21 PM

Once the structure was complete it was time to fill all the voids with foam then sand and shape the foam. The tail booms were spun on a lath to insure a prefect tapered shape.

Rotor George · 03-22-2009, 01:24 PM

After the shaping and filling of the plug was complete it was time to fiberglass it. Here we see the initial layer of 6oz glass cloth being applied to the various plugs.

Rotor George · 03-22-2009, 01:26 PM

Filling the glass cloth pattern is the next step. A thickened resin mixture is squeegeed out, once cured the surface is sanded smooth.

Rotor George · 03-22-2009, 01:29 PM

After alot of sanding, high build primer is sprayed and more sanding to achieve a smooth surface, then detailing can begin.

Rotor George · 03-22-2009, 01:33 PM

The window masking is the first step in the detailing process. All the window areas and "cut-out" areas are masked off then high build primer is applied leaving a recessed area after the tape is removed.

Rotor George · 03-22-2009, 01:36 PM

Rivets are the next step before the final finish coat goes on.

Rotor George · 03-22-2009, 01:40 PM

Final top coat is applied to give the plugs a nice glossy finish in preparation for mold making.

Rotor George · 03-22-2009, 01:48 PM

Here are a few detail items which will be applied to the finished parts. Items include scale vent grills, functional door hinges, cowling fasteners, landing gear saddles, the 407 intakes, and the list goes on and on.

Functioning door hinges

Fasteners, with screw heads at different angles.

The 407 vent intakes, different sizes for each side.

Rotor George · 03-22-2009, 01:58 PM

The making of the molds starts with the parting boards. The out line of each parts is traced out then cut out with a jig saw. The parts are then placed into the parting boards dividing each part down the center line.

03-22-2009, 01:15 PM	#1
Rotor George Registered Users Join Date: Nov 2008 Location: Tampa, FL	Scratch building 1/4 scale Bell 206B, 206L and 407 fuselages Last June I started scratch building three 1/4 scale fiberglass R/C helicopter fuselages. A Bell 206B Jet Ranger, a Bell 206L Longranger and a Bell 407. I wanted to make these for myself with the idea of having highly detailed parts complete with rivets right out of the molds. It all started with a cardboard structure cut and hot glued together.

03-22-2009, 01:21 PM	#2
Rotor George Registered Users Join Date: Nov 2008 Location: Tampa, FL	Shaping the foam Once the structure was complete it was time to fill all the voids with foam then sand and shape the foam. The tail booms were spun on a lath to insure a prefect tapered shape.

03-22-2009, 01:24 PM	#3
Rotor George Registered Users Join Date: Nov 2008 Location: Tampa, FL	Glassing the plugs After the shaping and filling of the plug was complete it was time to fiberglass it. Here we see the initial layer of 6oz glass cloth being applied to the various plugs.

03-22-2009, 01:26 PM	#4
Rotor George Registered Users Join Date: Nov 2008 Location: Tampa, FL	Filling the weave Filling the glass cloth pattern is the next step. A thickened resin mixture is squeegeed out, once cured the surface is sanded smooth.

03-22-2009, 01:29 PM	#5
Rotor George Registered Users Join Date: Nov 2008 Location: Tampa, FL	High Build Primer After alot of sanding, high build primer is sprayed and more sanding to achieve a smooth surface, then detailing can begin.

03-22-2009, 01:33 PM	#6
Rotor George Registered Users Join Date: Nov 2008 Location: Tampa, FL	Window masking The window masking is the first step in the detailing process. All the window areas and "cut-out" areas are masked off then high build primer is applied leaving a recessed area after the tape is removed.

03-22-2009, 01:36 PM	#7
Rotor George Registered Users Join Date: Nov 2008 Location: Tampa, FL	Rivets Rivets are the next step before the final finish coat goes on.

03-22-2009, 01:40 PM	#8
Rotor George Registered Users Join Date: Nov 2008 Location: Tampa, FL	Top Gloss Coat Final top coat is applied to give the plugs a nice glossy finish in preparation for mold making.

03-22-2009, 01:48 PM	#9
Rotor George Registered Users Join Date: Nov 2008 Location: Tampa, FL	Detail Items Here are a few detail items which will be applied to the finished parts. Items include scale vent grills, functional door hinges, cowling fasteners, landing gear saddles, the 407 intakes, and the list goes on and on. Functioning door hinges Fasteners, with screw heads at different angles. The 407 vent intakes, different sizes for each side. Last edited by Rotor George; 03-26-2009 at 05:29 PM..

03-22-2009, 01:58 PM	#10
Rotor George Registered Users Join Date: Nov 2008 Location: Tampa, FL	Molds The making of the molds starts with the parting boards. The out line of each parts is traced out then cut out with a jig saw. The parts are then placed into the parting boards dividing each part down the center line.

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