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  #501  
Old 03-22-2021, 04:31 PM
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AX-O AX-O is offline
 
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Not perfect out of the plug but super light and strong. Parts looked way nicer once cleaned and trimmed to fit. Pretty pictures later, for now raw parts will have to do.













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Axel
RV-4 fastback thread and Pics
VAF 2020 paid VAF 704
The information that I post is just that; information and my own personal experiences. You need to weigh out the pros and cons and make up your own mind/decisions. The pictures posted may not show the final stage or configuration. Build at your own risk. Further more, these are my opinions and not those of my employer.
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  #502  
Old 03-24-2021, 11:48 PM
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This was one of the scariest thing I have done to my plane. I had nightmares of foam stuck to my engine.

I decided to tape a heavy trash bag to the engine baffles and make a few dams around the engine to keep the foam contained. The foam needed to expand around items (lock in place). I used 2 part pour foam. Learned a trick from a long EZ guy around the airport. Poured the measured content in a zip lock bag. Mixed it, then cut the tip of one of the corners and poured it. Also if you let the foam start to set just a bit before you pour it, the foam becomes easier to control and runs less (sticks to other foam or surfaces).

After sanding through different layers of foam that were made from different pouring times, it became apparent that you want to try to keep the different pouring to a minimum. sanding between the layers became inconsistent.



















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Axel
RV-4 fastback thread and Pics
VAF 2020 paid VAF 704
The information that I post is just that; information and my own personal experiences. You need to weigh out the pros and cons and make up your own mind/decisions. The pictures posted may not show the final stage or configuration. Build at your own risk. Further more, these are my opinions and not those of my employer.
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  #503  
Old 03-25-2021, 12:50 PM
Ralph Inkster Ralph Inkster is offline
 
Join Date: Feb 2008
Location: Calgary, Alberta
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Brings back memories!
I completely foamed Bill Beaton's supercharged engine to fashion its custom cowl. Looked like the Pillsbury Doughboy's plane. Some how I managed to do it without any sticky residue left on the engine components. Sliced it off in upper & lower halfs.
Never again...
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built a few RVs, rebuilt a few more, hot rodded more, & maintained/updated a big bunch more
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  #504  
Old 03-26-2021, 09:44 AM
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After sanding down the foam it was time to make it a smooth as possible. I used fast dry wall putty and sanded it down once it was dry. once that was done, I used one of my favorite trick of using clay to determine how much space is available between parts. In this case between the plenum and the cowling.













Well this is a Problem!!





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Axel
RV-4 fastback thread and Pics
VAF 2020 paid VAF 704
The information that I post is just that; information and my own personal experiences. You need to weigh out the pros and cons and make up your own mind/decisions. The pictures posted may not show the final stage or configuration. Build at your own risk. Further more, these are my opinions and not those of my employer.
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  #505  
Old 04-06-2021, 12:01 AM
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I spent a long time trying to get the intake diffusers to line up right with the inlet rings. I laid a couple of layers of carbon fiber on the baffles to have a good contour of the surfaces. That would allow me to "glue" the already made diffusers in place at the right angles. The peel ply facilitated the process once pulled. I used standard West Systems epoxy with slow hardener. I have had good result with this on the last few plenums.















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Axel
RV-4 fastback thread and Pics
VAF 2020 paid VAF 704
The information that I post is just that; information and my own personal experiences. You need to weigh out the pros and cons and make up your own mind/decisions. The pictures posted may not show the final stage or configuration. Build at your own risk. Further more, these are my opinions and not those of my employer.
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  #506  
Old 04-08-2021, 06:10 PM
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Time to make the plenum. I used left over bi and uni directional carbon fiber from the Formula 1 race plane. In some places I have 3 layers and in some places 4. I purposely put arcs and sharp bends in the plenum design to add rigidity to the part. After the plenum was laid, I inserted nails in the previously drilled locations so I could match drill the parts together after the plenum was cured. I used 2 space heaters and got the temp inside the cowl to 140 deg for at least 8 hrs.















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Axel
RV-4 fastback thread and Pics
VAF 2020 paid VAF 704
The information that I post is just that; information and my own personal experiences. You need to weigh out the pros and cons and make up your own mind/decisions. The pictures posted may not show the final stage or configuration. Build at your own risk. Further more, these are my opinions and not those of my employer.

Last edited by AX-O : 04-08-2021 at 06:19 PM. Reason: added 1 more pic
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  #507  
Old 05-23-2021, 08:51 AM
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Time to address that dang valve cover that does not fit in the cowl. Started with a small hole that just got bigger and bigger and bigger!!!









Then I put tape on the vale cover and engine plenum. Glued nuts to a few spots to get a consistent clearance on the final product. Filled in with bondo so nothing would move once I started sanding.


Then used fast dry wall putty to fill in and contour the new cowl shape. This turned into a mold.


Then decided where I was going to cut the cowl once the part was removed from the mold.


Aluminum tape on the cowl so I can lay carbon fiber right on top of it.


Blue tape so I knew exactly where to cut the part. Once the part was off, I just cut the blue tape off the part and the cowl flange matches.


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Axel
RV-4 fastback thread and Pics
VAF 2020 paid VAF 704
The information that I post is just that; information and my own personal experiences. You need to weigh out the pros and cons and make up your own mind/decisions. The pictures posted may not show the final stage or configuration. Build at your own risk. Further more, these are my opinions and not those of my employer.
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  #508  
Old 05-23-2021, 09:02 AM
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plehrke plehrke is offline
 
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So cowl is asymmetric left to right?
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  #509  
Old 05-23-2021, 09:48 AM
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Quote:
Originally Posted by plehrke View Post
So cowl is asymmetric left to right?
Yes, by the width of a nut.
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Axel
RV-4 fastback thread and Pics
VAF 2020 paid VAF 704
The information that I post is just that; information and my own personal experiences. You need to weigh out the pros and cons and make up your own mind/decisions. The pictures posted may not show the final stage or configuration. Build at your own risk. Further more, these are my opinions and not those of my employer.
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  #510  
Old 05-23-2021, 09:54 AM
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Toobuilder Toobuilder is offline
 
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Quote:
Originally Posted by plehrke View Post
So cowl is asymmetric left to right?
Not speaking for Axel here, but I had to do a similar thing to clear an errant rocker cover on my Rocket. I cut a hole for clearance and just did a flat wrap of manilla folder stock to provide a bump on the left side. Glassed over and faired, its hard to spot unless you are looking for it, but my cowl is certainly asymetric.
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WARNING! Incorrect design and/or fabrication of aircraft and/or components may result in injury or death. Information presented in this post is based on my own experience - Reader has sole responsibility for determining accuracy or suitability for use.

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