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More wings, the hard way?

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tahoedirk
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More wings, the hard way?

Postby tahoedirk » Sun Feb 04, 2018 6:24 pm

I decided to try some medium sized all around kiting wings, maybe windsurfing too! These are about 580 an 680 cm2.
I tried something new with the formica templates, just one positive piece instead of top and bottom negative templates. It worked well enough and saved some time for sure.

I'm still just looking for the perfect smooth, sub 30mph bread and butter.

The upside down m shape is new and different for me.

These are just models for molds. I'm going to try to simplify and make short work of the molds.
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tahoedirk
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Re: More wings, the hard way?

Postby tahoedirk » Mon Feb 05, 2018 8:06 pm

Wow! Not a comment, addition or anything, I'm pouring my guts out, for years, every hard won tip that I can share.. I always hope I reach at least one interested builder.
Oh well here's more

The wings are close enough , sanded to 220 ,waxed and covered with hairspray , my new favorite mold release.

Here is my attempt at a simple mold. This fiberglass hanging over the wing is actually the first half and parting edge of the lower wing surface mold.

I hope It works

Happy building!


20180205_103252.jpg

plummet
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Re: More wings, the hard way?

Postby plummet » Mon Feb 05, 2018 8:20 pm

Looks cool man. Ive got nothing to added except have you added the fuse mounting radius to the mould?

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downunder
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Re: More wings, the hard way?

Postby downunder » Tue Feb 06, 2018 3:19 am

tahoedirk wrote:
Mon Feb 05, 2018 8:06 pm
Wow! Not a comment, addition or anything, I'm pouring my guts out, for years, every hard won tip that I can share.. I always hope I reach at least one interested builder.
Oh well here's more

The wings are close enough , sanded to 220 ,waxed and covered with hairspray , my new favorite mold release.

Here is my attempt at a simple mold. This fiberglass hanging over the wing is actually the first half and parting edge of the lower wing surface mold.

I hope It works

Happy building!



20180205_103252.jpg
Yes, that's how it is man. Spent 7 years blogging, next 5 years on different forums...Takes muchos time and effort!

If you're making a molds from a foam, what you'll use in the mold?

tahoedirk
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Re: More wings, the hard way?

Postby tahoedirk » Tue Feb 06, 2018 4:57 pm

20180205_172313.jpg
Ready for wax , hairspray and 10 layers of 6 oz on a bias
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10 layers for the top of the mold
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Looks promising!
The molds are a bit flimsy but I think with a hot coat and some work I can get them stiff and shining. I will probably make a quick and dirty wing first though.

The wings took a lot to build but this mold build was pretty darn easy

Carbon time

TomW
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Re: More wings, the hard way?

Postby TomW » Tue Feb 06, 2018 8:22 pm

I think I get your process.?
Make wings in foam. Shape and one layer of glass. Sand smooth. Now you have plug.
Hairspray release.
Put one layer glass one one side " hanging over". cure it.
Flip it and put on 10 layers glass. Cure
Repeat 10 layers for other side.
Remove each side.
Reinforce molds somehow.

Interested how you do laminating into mold.

Blackrat
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Re: More wings, the hard way?

Postby Blackrat » Wed Feb 07, 2018 2:08 pm

Surely it's faster and easier to vac 3 layers of carbon over the foam core and use it ?

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downunder
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Re: More wings, the hard way?

Postby downunder » Wed Feb 07, 2018 4:49 pm

It will snap at the fuse due to Compression. Needs something other than a foam there...thats why I asked the question, whats in the mold as a core?

tahoedirk
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Re: More wings, the hard way?

Postby tahoedirk » Wed Feb 07, 2018 5:02 pm

Yes Tom, you got it exactly. Layup is what you make it, either pre cut many layers with different sized piece or just concentrate on the outer layer and fill the mold.

No foam anymore DU just carbon , first wings were 20 oz biax skin and then 20 and 8 oz uni inside.

Yes Blackrat you would think so, but no. Every time I glass a wing, I say never again. There is no easy way to wrap and finish the LE. You fill the center, fiddle and sand and mess up the profile over and over and you are still left with a less than bomber piece. A mold is so much easier to layup and I like a solid carbon wing, especially in this size range. My 1600 would weigh 4kg and start a fire if it was solid though. Solid parts do not break or dent ,they are easily refined, they fix easily and last forever.

I'm looking for my best parts yet , it is hugely time consuming. I am not making much money in the end, but it is very satisfying and I know there are not many who are this deeply involved in foil design, especially handbuilding in the mountains in winter naked. ok I made up the naked part

tahoedirk
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Posts: 210
Joined: Sun Aug 31, 2014 5:02 pm
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Local Beach: Kings beach, CA
Favorite Beaches: All clean beaches
Style: out of control
Gear: Homemade gear
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Re: More wings, the hard way?

Postby tahoedirk » Wed Feb 07, 2018 5:58 pm

At least I have something now for my 8 days of work

It was essential to not overfill my floppy ass mold, .

I want to try them now


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Flimsy mold does not like clamps
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Cooperative hairspray. Not too rough
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These look good enough for now
Happy building people!!


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