Second batch of ribs just cured - going into the oven tomorrow for post curing.

My latest video offering - - shows how the ribs are laid up before infusing. Riviting stuff... but I thought I might as well document how I'm doing each step in fabricating an all-Carbon Dragon!

That's more or less all the main wing ribs done - just have to do the #2 ribs, which I am going to re-jig a little. The original plans call for a one piece #2 rib and a two part drag spar glued either side of the rib. I think it makes more sense to fabricate the drag spar in one piece (for greater strength) and split the #2 rib instead. I'll make the #2 rib moulds once I have the exact dimensions, point of intersection and angles of the joins all worked out.

Phil.

---

From: This email address is being protected from spambots. You need JavaScript enabled to view it. [This email address is being protected from spambots. You need JavaScript enabled to view it.] On Behalf Of KarlS
Sent: 07 April 2012 14:45
To: This email address is being protected from spambots. You need JavaScript enabled to view it.
Subject: [Carbondragonbuildersandpilots] Re: Phil's CD - resin infusion



Pretty cool Phil. Thanks again. Your video shows the real McCoy of what is done and how it is done.

Looking forward to see how you trim it up. Your trim table sounds like it will be a nice tool as well.

Karl

--- In This email address is being protected from spambots. You need JavaScript enabled to view it., "Philip Lardner" wrote:
>
> Hi Karl,
>
> Busy week here, with all sorts of things distracting me away from CD work!
> However, I did get my first batch of ribs post-cured and demoulded. I
> haven't trimmed and finished them yet - I'm building an adjustable table/jig
> to hold my high-speed multi-grinder (Dremmel type tool) this weekend and
> will post details of that when it's all working.
>
> The ribs (in the rough) look great - the female moulds worked a treat and I
> will do the next batch next week, hopefully. In the meantime, here are a
> couple of videos showing the debagging and demoulding process.
>
> Debagging the cured parts after 48hrs curing at room temperature:
>

>
> The parts were post-cured in an electric (kitchen) oven for
> <blocked::mailto:4hrs@40C> 4hrs@40C, then
> 4hrs@50C, 4hrs@60C and finally
> <blocked::mailto:4hrs@80C> 4hrs@80C. This is a bespoke regime given to me by
> the resin manufacturer for a higher final temperature than they normally
> advertise, and specific to this particular resin.
>
> Demoulding the post-cured parts: <

>
>

>
> Coming soon... trimming and finishing the parts...
> Enjoy!
>
> Phil.
>
> _____
>
> From: This email address is being protected from spambots. You need JavaScript enabled to view it.
> [This email address is being protected from spambots. You need JavaScript enabled to view it.] On Behalf Of KarlS
> Sent: 06 April 2012 19:32
> To: This email address is being protected from spambots. You need JavaScript enabled to view it.
> Subject: [Carbondragonbuildersandpilots] Re: Phil's CD - resin infusion
>
>
>
>
> Hello Phil,
> I was just wondering how your parts turned out? Hopefully well.
> Karl
>
> --- In This email address is being protected from spambots. You need JavaScript enabled to view it.
> <mailto:Carbondragonbuildersandpilots%40yahoogroups.com> , "Philip Lardner"
> <philiplardner@> wrote:
> >
> > Hi Folks,
> >
> > Thought this might be of interest - I infused my first batch of ten wing
> > ribs yesterday evening, Three hang gliding friends came along to watch the
> > process... one of whom is taking a serious interest in the Carbon
> Dragon...
> >
> > The moulds are very easy to set up, and with just a little care, all signs
> > of bridging between the mould and the work surface can be easily removed
> > with my favourite kitchen implement! My workshop is cooler than my kitchen
> > (where I infused my initial test pieces) so I'll leave this batch to
> > complete its initial cure for 24 - 48 hrs before I de-bag and trim them.
> So
> > far, all the signs look good. I really am impressed (as were my friends)
> at
> > just how clean the infusion process is - no mess or sticky hands
> whatsoever!
> >
> > My only mistake was in thinking I needed one last pot of resin... most of
> > which ended up in the catch pot. I had to remove that to outside the
> > workshop before it exothermed and started a fire. Being able to clamp off
> > the vac-bag from the catch pot to change the paper cup inside is very
> > useful!
> >
> > One other very useful lesson learned was that I it would be easier (for
> the
> > purposes of eliminating bridging) to cut separate pieces of peel ply for
> > each rib rather than (as I did this time) use a single large piece of
> cloth
> > to cover all the ribs. Cutting the infusion mesh layer in strategic places
> > (but not into separate pieces) between the ribs also greatly assisted in
> > removing bridging.
> >
> >

> >
> > Enjoy,
> >
> > Phil.