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-   -   Composite Warbird Build 1/7th P-40E Warhawk (https://www.wattflyer.com/forums/showthread.php?t=32640)

Slow & Low 03-30-2008 02:41 AM

Composite Warbird Build 1/7th P-40E Warhawk
1 Attachment(s)
Hello All,

I've recently posted a video of my ongoing build of my latest all composite warbird. Feel free to have a look and leave me some feedback. Please be nice.;-)

You can find it here on my channel http://www.youtube.com/user/b1heqh54

or here [media]http://www.youtube.com/watch?v=-ge3yw99b9g[/media]

worldraft 03-30-2008 06:06 AM

At what scale is your P40. I asking because I'm building a Zeroli P40 & it's supose to be 1/5 scale. By the way I realy like your built and the moulding part as well. How many layers of Cloth did you use and what thickness were they????

Slow & Low 03-30-2008 07:56 AM

Hawkesbury Wow - Is that you that I see by the bridge on Google Earth? LOL Man, you must be right on the border there eh? That's a very nice bird you're building there. Mine is 1/7th scale. It's a .60 size 2 stroke or 1.00 4 stroke plane. Wingspan's 64" not like your 94". I built this one to fit in the average size car so that my friends and I could get them to the field without a lot of consideration. I was just sitting here updating my Solidworks to 2008 so that I can draw up the next one. I've been waiting to see how much parts were going to weigh as the came out of the mould before I scale the next one. I'm thinking 1/4 scale 112" span! I haven't got a complete plane yet so I'll wait to finalize that, but the model will be parametric and scaleable anyway. You've asked a good question, and when I start the other side in a couple of days I will do a better series of time lapse shots for you indicating the various cloths etc with a clock in the background so you can really see what's going on. I kept it pretty simple - the typical schedule was

1 coat tooling epoxy
1 X 3/4 Oz/ft^2 biaxial weave to get into the corners
1 X 1-1/2 Oz continuous strand surface veil to stop the heavier weaves from showing through over time
1 X 2 Oz biaxial weave as a nice transition before heavier cloth
8 X 7-1/2 Oz biaxial weave (surfboard stock from California USA - cheap)

I use epoxy resin all the way through. I'm fortunate enough to be able to work at it 24hrs/day so I let the epoxy set for around 7hrs in between coats. So you can see that it's about 4 days of working around the clock to do a section. I'm just catching up on my sleep from the first side now!! lol Keep an eye on the youtube channel, and I'll try to post here too. Always nice to meet another Canadian on here! Got any pics of yours around? Before I came up with this plan, I always wanted to do the build you're working on, so I'd like to see it 4 sure. I've flown P-40E's forever. (I'm kinda crazy that way, I'm not sure what Freud would say but I don't know if I care either LOL) I've even still got my first control line profile Warhawk somewhere around here - WOW I must've been about 12 - I'm 38 now - ouch time flies

pd1 03-30-2008 01:34 PM

Slow & Low, Welcome to Wattflyer.
Nice build.
What epoxy are you using?
What do you estimate the final weight to be?
If you answered these questions in the video, sorry. My computer doesn't have sound.


worldraft 03-30-2008 03:07 PM

My build
Hi S & L if you think your Slow lol U haven't seen anything yet. Oh by the way I'm 4 Km from the Quebec line.
My built is on my web site & it can be found under my name in the post.

Slow & Low 04-10-2008 07:25 AM

Hello All,

Well, I've made a couple of new videos since my last post that you can check out here http://www.youtube.com/user/b1heqh54
I'm surprised at how popular they're becoming, I just put them up there for some of my friends to look at!

Paul, I'm hoping that it will come in around 7lbs all up - you can see the epoxies that I'm using in the videos. Actually just the tooling epoxy for now, because I'm working on the laminating video now. But if you're anxious I can email you spec sheets.

Thanks for watching!

worldraft 04-12-2008 02:51 AM

Good video
I've just been watching your video aand it's awsome. I had a fiberglass business a while back and I made molds, but they were one part things not complex like yours. I'm building a P40 as well, and when it's finished I see if i'm going to do this but I'll find som thing to do as practice first.
All in all very cool, thanks for the video.

Slow & Low 04-18-2008 02:24 AM

I can't believe it's been a week since my last post - man time flys!!
At any rate, I put together another video today that you may find useful if you've never built a mould, but have thought about trying. I've tried to show that it's something you can leave overnight, or while you're off to work, and come back to at the end of the day for another go around. Well, you can have a look here http://www.youtube.com/user/b1heqh54 - the next one will be quite a bit sooner in coming - and there's some drama too!!! lol :)

Slow & Low 04-23-2008 08:09 PM

Just a routine thread update.
Well, I can see the number of views increasing still, so I'll just keep on posting! lol
I promised drama - if you like to see someone else frustrated with themselves, then this video is for you. The build is moving along, despite my best efforts to hold myself back http://s3.images.proboards.com/smiley.gif
This is the fifth episode in the series that I'm putting together at the request of a few others who thought that they would like to see a little more detail in the mould construction, and you can see it here http://www.youtube.com/user/b1heqh54
Feel free as always to leave a comment or question - or tell me I'm crazy if you like - you won't be the first, and probably not the last - cheers everyone - enjoy

Slow & Low 04-30-2008 09:12 PM

Video Update
Since the last video, I've completed a couple of more sections to the mould and am moving along. I've had more than a few questions about why I chose to make the mould in so many sections. So I decided that since I'd recently completed four sections that make up the rear of the mould, I would take a few minutes to put together a quick video. I hope this helps to answer the questions, but it wasn't easy to do with the limited studio budget - lol
You can see the latest video here http://ca.youtube.com/b1heqh54
I can see that finished squadron of fuselages already! :)

Slow & Low 05-03-2008 10:48 PM

Paris Hilton Stops By to Lend a Hand
1 Attachment(s)
OK - so I wasn't happy with the last video that I threw together
Too much, too little, and I just wasn't happy.
Anyway, Paris Hilton owed me a favour - so check out the latest vid here

I'm also putting together a little vid on the cheap vacuum system, I just put together for this project - here's a pic, let me know what you think
PS. - I purged those tanks very carefully first with air, then with water - I am not promoting this sort of thing - take them to your Fire Department and ask for their help

Slow & Low 05-25-2008 06:17 PM

DIY Fuselage Mould Build Update
Well Jean, here's another video update if you're interested.
I've checked out your P40 build on your website. Lookin' good, have you made any progress since those pics?

The latest video is number seven in the series that can be found on my youtube channel at this link here... www.youtube.com/b1heqh54

worldraft 05-28-2008 05:25 AM

No the last pic date back a while now because spring is here and I will be working on it at a slower pace.

Slow & Low 06-03-2008 05:45 PM

Pic Update Complete Fuselage Mould
6 Attachment(s)
...just a quick pic update today
There will be another video shortly, but I wanted to keep the thread updated.
I've completed all of the mould sections, and will now move on to some access holes to allow for construction.

Slow & Low 06-07-2008 11:55 PM

P40 Warhawk Fuselage Mould Complete
Well video number 8 is now available on my youtube channel and can be seen on this page here www.youtube.com/b1heqh54
This episode is all about sacrifice and glory! lol

Slow & Low 06-19-2008 09:05 AM

P-40E Composite Fuselage Pics
6 Attachment(s)
I just finished pulling the first fuselage for the P-40 project. There will be another video very shortly to answer some more questions for you "how-to" types.
As you can see, there is still some flash to trim up, but the functionality of the tool has been validated. I also tried a few different experiments with seam joining and layup technique, so if you look closely you will see some variations. All in all, it will serve the pupose and I can fly my plane without fear of pushing the envelope. The weight is 1.6lbs or 0.73kg. It's probably a little on the heavy side, because I wasn't too concerned at this point.

wilmracer 06-19-2008 12:26 PM

Looks Great! :$

So when can we order ;-)

Slow & Low 06-19-2008 12:43 PM


Slow & Low 06-21-2008 07:28 PM

The final video in the fuselage mould how-to video series (#9) can now be found on my youtube channel on this page here www.youtube.com/b1heqh54
Good luck with your own projects! It's been a blast.

Slow & Low 10-03-2008 06:55 PM

Inspired by a friend.
A Builder's Soul.

Building season's back again, that chill is in the air.
Soon the winter storms will blow, yet somehow I don't care.
There's solice in a friend they say, and yes I'll say that's true.
But all alone with wood and glue I'll find it in this too.

Another summer come and gone, the gentle breezes blew.
I found myself in air aloft on wings my fingers knew.
Far above my cares I soared, lifted up to better times.
Try to tie me to the ground but those memories are mine.

Building season's back again, that chill is in the air.
Soon the winter storms will blow, yet somehow I don't care.
There's solice in a friend they say, and yes I'll say that's true.
But all alone with wood and glue I'll find it in this too.

And now the winds of change are here that warn of colder times.
I'll shut myself inside my house, don't worry I'll be fine.
You see I'm building times remembered that once my father knew.
Crafted from a soul some say he made from wood and glue.

Building season's back again, that chill is in the air.
Soon the winter storms will blow, yet somehow I don't care.
There's solice in a friend they say, and yes I'll say that's true.
But all alone with wood and glue I'll find it in this too.

Nothing more than dreams it takes to fly to higher heights.
I still hear those words from him when I'm alone at night.
And so as winter's winds will blow and keep me on the ground,
Alone in precious silence is where you know that I'll be found.

I'll build another ship of hope to sail without a care.
From dreams and dust I'll rise again to challenge summer's air.

- A builder.

Slow & Low 10-04-2008 05:16 PM

Weight Comparison Balsa & Ply vs Fibreglass
Alright then, here we go concerning weights.
Before I get into it, I should begin with a few thoughts.

Concerning the fibreglass fuse.
This layup was only intended to validate the function of the mould and as such I wasn't overly concerned with weight.
I used 7Oz cloth rather than 6Oz - so that will likely save a couple of ounces.
I didn't vacuum bag it - so there will be a slight savings in an improvement of epoxy to cloth ratio there.
I put 5Oz of acrylic paint into the epoxy that wasn't necessary but I wanted some contrast so that I could verify the detail transfer from the mould.
I haven't installed ply for the motor mount, battery tray, or wing mounting blocks, but there's also extra material in the nose of the fibreglass shell yet to be removed in that nose.
All in all I expect these factors to amount to an additional reduction of around 7Oz's in the next layup schedule.

Concerning the plug.
There's alot more filler in the plug than I would've put on a flying model in order to achieve scale outline etc.
There's additional materials in the nose and wing saddle area to facilitate mould construction.

There are no control surfaces on either one at this point.
Alright then...

As it stands now
Plug weight - 49Oz or 3.1lbs
Fibreglass fuse weight - 32Oz or 2lbs even
net reduction - 35%

Considering projected weight reduction of 7Oz's in next layup
Plug weight - 49Oz
Fibreglass fuse weight - 25Oz or 1.56lbs or 1lb 9Oz (this is about what I would expect to see)
net reduction - 49% reduction

I still have a couple of tricks up my sleeve, but I think I'm track anyway.
Just out of curiosity does anybody out there have a fuselage in the works without control surfaces on it yet? I'd like to know what one would come in at without all the filler and extra material on it.

pd1 10-05-2008 02:08 PM

Just thought you should know, You're doing a fantastic job on ths plane.
Looking forward to the finished product, and flying.


Slow & Low 10-05-2008 04:57 PM

Thanks for following along Paul. I hope that you are as patient as I am, because it's likely gonna take some time. It should all be worth it in the end though;)

Slow & Low 11-30-2008 05:00 AM

Glassing the P-40 Wing
4 Attachment(s)
Well, with the cold weather back in town, I've been spending some time with my P40 again. With the fuselage mould complete, I now have to finish a wing so that I can get on with the moulding.
After months of sanding filler and primer in my spare time, I've come to the point in the road where I'm satisfied that the form of the wing is good enough to lay down some glass cloth. This is always the hardest part for me - moving on. I always want things as close to perfection as I can get them before I lock it in with glass, but at some point you have to just stop and lay the dang cloth down! (Tip symmetry drives me nuts!)

If you're new to this operation, here are some things to note. Most of all, don't be discouraged from trying it! Personally, I think it's a lot easier than film - and there's more sanding fun to be had! lol

- I mixed equal parts of resin, hardener, and methyl hydrate (denatured alcohol in USA) in order to get a nice thin watery consistency. Don't fill the weave, just wet the cloth out and let it dry.

- Don't trim too closely (the weave will move around as you brush and what looks like it may fit, may not by the time that you get there. If you run a sanding block aroung the edge once it's dry, the excess cloth will pretty much fall off leaving a nice edge.

- Start in the middle and work outwards.

- Don't try to do too much area at one time, and don't worry about overlapping sections. You won't be able to see these seams after a finish coat of epoxy later.

Slow & Low 12-02-2008 09:59 AM

9 Attachment(s)
Wing is glassed.

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