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Author Topic: Foam Quark  (Read 20482 times)

johnfireball

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« on: December 20, 2011, 21:18:03 PM »


Hi all,
     Having never worked with foam before I have decided to have a go at making a foam 1.6m Quark as per Freds plan. Two unsuccessful attempts with an assistant at wing cutting in one go I decided to try it in two stages.I started by cutting blocks of foam 5mm all round bigger than wing size  I soldered wires to the templates(in the pic the wire is broken off the back of the root template, I caught it in my jumper). I double sided taped the templates to the block ends (checking allignment) and with an assistant managed to cut 2 opposite and useable wings in two passes per wing of the hot wire.  They needed a little sanding to remove lines caused by slow wire speed at the wingtips. Cutting wings this way requires a little sanding of the leading edge ( you can see the waste that needs removing on the leading edge in pic.) and cutting a sliver of foam from trailing edge using a knife and steel rule.
             The small wing below the foam is a test piece which has the same profile as the quark wing. After it was cut I rolled it with a coat of PVA glue, allowed it to set off somewhat I then glued out craft paper using the same glue and roller and covered the wing top and immediately after covered the bottom and then weighted it down to dry. The result is a good stiff wing which hardly requires a spar although I will fit one.
            Paper finish is difficult to paint so I will most likely be taping also.
John.
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johnfireball

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« Reply #1 on: December 21, 2011, 21:14:29 PM »



Some progress, have glued in 5mm solid carbon spar and tubes for 6mm wing mount. I used my soldering iron with a ruler to melt out the spar channels. The incidence pin tube is 5mm brass with 4mm carbon pin. I have taped  carbon strips to the trailing edges and will hopefully get a better sharper finish.
   I have tried a water based varnish to seal the craft paper and it works really well as a base coat for spray paint, so might not use tape. Waiting on lightweight filler to dry and will then cover.
John.
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Fred

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« Reply #2 on: December 23, 2011, 15:22:45 PM »
Hey John,

This is looking very good.
Are you going to use the same foam to make the fuselage ? :clap:  :clap:
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johnfireball

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« Reply #3 on: December 23, 2011, 19:45:17 PM »
Hi All,
      Some more progress made.



 I had to laminate foam pieces together as my foam was not thick enough. I cut the templates from hard cardboard 1.4mm thick, they work but not great (cutting wire catches).

I have now covered the wings and completed the tailplane which I made from foam  sanded to shape, added carbon trailing edge and covered.
 The wings are now weighed down in their outer covers and will remain there for a few days to dry out. The paper and pva dry out very rigid and hopefully wont warp. This so far is the cheapest model I've built as all materials I had to hand. It's a bit of an experiment and learning as I go but  so far pleased with results. It's my thrifty recession Quark.
 

John.
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mario

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« Reply #4 on: December 23, 2011, 20:32:12 PM »
good job :wink:
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Fred

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« Reply #5 on: December 24, 2011, 10:29:34 AM »
Looking good John  :clap:

An old trick when using cardboard template is to rub graphit on the edge ( from a pencil) that make the wire glide on the cardboard  :D

Looking forward to the completed model
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johnfireball

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« Reply #6 on: December 26, 2011, 00:40:58 AM »
Happy Christmas to all,
Yea I know its Christmas but no better time to melt foam.
Build progress, fuse complete and servos fitted just needs fin and connections. I fear she may be getting a little fat and will probably weigh similar to my phase. I like the look (very French if you know what I mean). It is perhaps an early Citroen. Can't wait to fly her(it'll go like stink and then I'll break it)
Happy new year,
John.  

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Fred

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« Reply #7 on: December 26, 2011, 12:01:22 PM »
God John, you are on fire !  :lol:

Your Quark is looking really good !
First flight should be soon, looking forward to that ! And let me know if you to Kilakee!  :D
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johnfireball

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« Reply #8 on: December 28, 2011, 01:45:04 AM »
I'm Baaack,
               
 Foam cut sanded and ready for covering


Wing servos and horns fitted and glued used hot glue gun to glue in servos and epoxy for horns.

I'm enjoying my venture into foam and paper and learning different techniques if I could turn back the clock I would hinge the ailerons as I have the fin, I would then not have any plastic hinge tape on the model and could then finish paint it with household emulsion of which I have loads of in the shed. I may mask off the hinges and use a cobination of acrilic and emulsion. I started this build as low budget and will try hard to keep it so. Its killing me having to buy a 6mm carbon rod joiner I,m using a wooden dowel to line up the build. The fin really brings this glider to life
Hi Fred,
           Great if you come to Killakee I am planning an elevon tailplane mix perhaps to do flips, airframe weight with servos 620 grms. She's a fab looking glider and I look forward to maiden which is not far off (will let you know). By the way only live round the corner from you.
John.
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johnfireball

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« Reply #9 on: December 29, 2011, 17:06:28 PM »
Got her finished today, rather pleased. I learned a lot with this build and many things I would do differently so if anyone is thinking of having a go with paper and foam I can give advice .  



Rearview with kids. I painted it with household emulsion. I needed a lot of noseweight 200grms, bringing total to 1000 grms. so it'll fly and crash fast (gulp). Just need to get 6mm carbon rod for wing joiner and she's good to go. Forecast is gruesome all weekend and next week so will have to be patient.



Next project Santa sent. Plan is to convert to rc electric, its 28" span and being new to electric advice on motor size, lipo etc would be appreciated.
John.

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Happy Days

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« Reply #10 on: December 29, 2011, 17:24:59 PM »
Well done John, :clap:  and it's nice to see a couple of young “pilots-to-be.” Did you make them out of foam & paper as well?

But I have a question John:

How are you going to stop the two wing halves from coming away from the fuse when in flight :?:  

From your pictures I haven’t seen any method of holding the wings to the fuse.

Keith
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johnfireball

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« Reply #11 on: December 29, 2011, 22:48:04 PM »
Hi Keith,
          The wings are held by short pieces of silicon tube on a forward wing pin. It's a bit tricky to assemble but hopefully will do the job. On my plouf I put thin strips of masking tape on the wing joiner rod and these hold ok with friction and dont wreck the fuse on hard landing. I will only use the silicon tube if the wings loosen up as they are holding firmly at present with friction alone.
John.

 
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Fred

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« Reply #12 on: December 30, 2011, 09:38:18 AM »
Hey John,

Your Quark is really looking good!  :clap:  :clap:
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johnfireball

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« Reply #13 on: December 30, 2011, 19:12:17 PM »
Hi all,
There maybe a weather break tomorrow so might get first hopefully not last flight in before the new year, anyway batteries are being charged.
John.
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Fred

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« Reply #14 on: December 30, 2011, 21:10:37 PM »
Hey John,

Do you know around what time you are going to fly?
Can come, but have to leave relatively early in the afternoon.
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