Quote:
Originally Posted by kach22i
That sounds like a good method for making multiple copies, but if interested in a "One-Off" could one use fan-fold insulation over the plywood forms and then cover it all in fiberglass cloth and epoxy resin?
The plywood (serial model) bucks would have to be trimmed down all around for the thickness of the composite assembly.
Looks like a lot of work went into this project.
Thank you for sharing.
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Yes,you could do it,but the bulkheads you see are already at the net dimension,so all of them would have to be shaved down by the thickness of the foam or she'd be 'pregnant'.
For what I have,dowels would be placed into the bulkheads,then expanded metal lath wired on to form an armature,to which the tooling plaster would be applied with splines and struck to the net contour.
bondo would use professional thermo-set modelling clay.
Orange shellac would seal it for primer and topcoat,then color-sanding and filling until an OEM surface was achieved.Maybe 1,000 man-hours.You'd really want to do it!
Rutan just uses blue foam and epoxy-composite skin.They must pay great attention to the exterior surface.