I'll start by saying that I'm a super noob at making composite things which will be obvious when you see the pics but I've made something that seems to fly well!
I was watching some of Nate's videos and got inspired to build a cnc foam cutter a few months back hoping to maybe make a combat wing or two. I ended up making a bunch of different combatish wings for Scott and me and had a blast doing it and learned a bit about the foam cutter.
Fast forward to now and we're 3d printing molds and bagging wings. I've bought a vacuum pump, have rolls of fiberglass, kevlar, bunch of resin(resin research) rolls of carbon tow etc. I kinda went crazy but supplies but I'm having so much fun doing it I just dont care!
Here is the fuse mold
![IMG_4180[1].JPG](https://forum.alofthobbies.com/index.php?attachments/img_4180-1-jpg.20858/ "IMG_4180[1].JPG")
And here is the first complete glider
![IMG_4181[1].JPG](https://forum.alofthobbies.com/index.php?attachments/img_4181-1-jpg.20859/ "IMG_4181[1].JPG")
The fuse is pretty light at 68 grams and the wing is super light also with only 1 layer of 1.4 oz and 1 layer of 3.7oz glass. I hadn't tried the bladder seaming yet so its just splooged together. I also painted the mylars on this one which worked great! Total auw is 440 grams. Its really light and flies in hardly any wind. I've been ds'ing it at the beach and it's a blast. It really gets moving despite the super light weight.
The second glider went to Scott. I went a little heavier on the fuse layup(90 grams) and the wing has 1 layer of 5.7oz carbon. Auw is 550 grams on that one. Its noticeably faster with the extra weight. Scott will have to post a pic of it as I dont have one
Here is the third one
![IMG_4184[1].JPG](https://forum.alofthobbies.com/index.php?attachments/img_4184-1-jpg.20860/ "IMG_4184[1].JPG")
This one has a heavier fuse layup at 120 grams and a heavier wing layup with one layer 1.45oz/one layer 5.7oz carbon and one layer 4 oz glass. with the painted fuse the auw is 690 grams. I actually just finished this one so haven't flown it yet but I know its gonna rip!
Here are some 3d printed parts I'm using to build it
![IMG_4188[1].JPG](https://forum.alofthobbies.com/index.php?attachments/img_4188-1-jpg.20861/ "IMG_4188[1].JPG")
Ive been trying to learn fusion 360 and made these parts with it. I bag the ribs in and then attach the tips with some 3mm carbon rod. The center piece was Scott's idea. He made a wooden one when he built his so I made us one in fusion to speed things up. We dig the foam out and epoxy it in when putting the wings together. It has holes for the servo wires/mounting screws and a 6mm rod for a "spar"
I'm using the 25psi foam from lowes/kevlar hinges/carbon braided sleeve with foam for the fin/uni carbon from root to tip 2" wide centered on the cg.
I'm having trouble getting a solid leading edge. Ive used kevlar by itself/kevlar sandwiched in glass/ and glass kevlar carbon sandwich and its still soft. I've been trying to find 60 psi foam with no luck in hopes that it will help. I keep looking at my Jester wings wondering how the F@ck he does it
I would love any tips on making the glider better!
Oh ya, the airfoil is the PW98mod. I chose it after reading an article from Peter that its good in lighter lift. Wingspan is 46"/ root is 180mm/tip is 120mm
I was watching some of Nate's videos and got inspired to build a cnc foam cutter a few months back hoping to maybe make a combat wing or two. I ended up making a bunch of different combatish wings for Scott and me and had a blast doing it and learned a bit about the foam cutter.
Fast forward to now and we're 3d printing molds and bagging wings. I've bought a vacuum pump, have rolls of fiberglass, kevlar, bunch of resin(resin research) rolls of carbon tow etc. I kinda went crazy but supplies but I'm having so much fun doing it I just dont care!
Here is the fuse mold
And here is the first complete glider
The fuse is pretty light at 68 grams and the wing is super light also with only 1 layer of 1.4 oz and 1 layer of 3.7oz glass. I hadn't tried the bladder seaming yet so its just splooged together. I also painted the mylars on this one which worked great! Total auw is 440 grams. Its really light and flies in hardly any wind. I've been ds'ing it at the beach and it's a blast. It really gets moving despite the super light weight.
The second glider went to Scott. I went a little heavier on the fuse layup(90 grams) and the wing has 1 layer of 5.7oz carbon. Auw is 550 grams on that one. Its noticeably faster with the extra weight. Scott will have to post a pic of it as I dont have one
Here is the third one
This one has a heavier fuse layup at 120 grams and a heavier wing layup with one layer 1.45oz/one layer 5.7oz carbon and one layer 4 oz glass. with the painted fuse the auw is 690 grams. I actually just finished this one so haven't flown it yet but I know its gonna rip!
Here are some 3d printed parts I'm using to build it
Ive been trying to learn fusion 360 and made these parts with it. I bag the ribs in and then attach the tips with some 3mm carbon rod. The center piece was Scott's idea. He made a wooden one when he built his so I made us one in fusion to speed things up. We dig the foam out and epoxy it in when putting the wings together. It has holes for the servo wires/mounting screws and a 6mm rod for a "spar"
I'm using the 25psi foam from lowes/kevlar hinges/carbon braided sleeve with foam for the fin/uni carbon from root to tip 2" wide centered on the cg.
I'm having trouble getting a solid leading edge. Ive used kevlar by itself/kevlar sandwiched in glass/ and glass kevlar carbon sandwich and its still soft. I've been trying to find 60 psi foam with no luck in hopes that it will help. I keep looking at my Jester wings wondering how the F@ck he does it
I would love any tips on making the glider better!
Oh ya, the airfoil is the PW98mod. I chose it after reading an article from Peter that its good in lighter lift. Wingspan is 46"/ root is 180mm/tip is 120mm
