I had never used a hot wire before I built my plugs. I borrowed a transformer and made a bow for the wire. The transformer had a dial that went from 1 -10. I didn't know what to use so I figured I would start in the middle at 5. When I turned it on it looked like a light bulb burning out with smoke where the wire used to be. (hmmm...must be set a little high....) I still ended up with the wire being pretty hot so it would cut faster. If it cut slower and the center lagged way behind the ends like it did in your video, the center was cut much lower than the ends when cutting curves. It did make for a rougher finish and prouced fumes that would know you over.



From: KarlS <This email address is being protected from spambots. You need JavaScript enabled to view it.>
To: This email address is being protected from spambots. You need JavaScript enabled to view it.
Sent: Wednesday, June 19, 2013 9:42 PM
Subject: [Carbondragonbuildersandpilots] Re: Phil's Carbon Dragon - progress...


Looks like fun Phil.. lol...

Have you ever hot wired foam panels? It's pretty easy to make a system to do it out of stuff from your local home repair stores. I've had good success with a lot of projects. Here's a link to my auto cutter at work. Warning.. it's boring.



Also another link to my Pitts Model 12 model I just finished this spring if you guys have some time to kill. Now that this thing is done I am free for the next project. Hmmm..

www.modelairplanenews.com/blog/2013/05/2...icks%20%26%20more%21

--- In mailto:Carbondragonbuildersandpilots%40yahoogroups.com, "Phil" wrote:
>
> Hi Folks,
>
> Just thought you might like to see a short video of part of one of the leading edge mould plugs being fabricated.
>
>

>
> I did try another method of making the moulds first (lining 'negative' formers with a sheet of 0.5mm polycarbonate) but I couldn't get the polycarbonate sheet to conform perfectly to the formers no matter how hard I tried! So... I reverted to using the old, tried and tested method of gluing blocks of polyurethane foam between 'positive' rib formers and sanding... sanding... sanding..!
>
> I hope to cover the polyurethane plug I just made with fiberglass this weekend and perhaps even lay-up the carbon fiber in the new mould next week if all goes well.
>
> Enjoy,
>
> Phil.