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#wing

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TomKrajci 🇺🇦 🏳️‍🌈 🏳️‍⚧️

How to remove/demold a part from a fragile part. (Hint: You can create shear in more than one way, and it may be better than creating a peeling action with hammer and chisel.)

The blue Styrofoam that served as the form will be destroyed as it's removed from the fiberglass wingtip weel, but it's a one-off form/mold that lacked any taper.

(This is a follow up to universeodon.com/@KrajciTom/11 )

#avgeek #aviation #ElectricAircraft #ExperimentalAviation #homebuilt
#Glider #DIY #Wing #Epoxy #Fiberglass #Composite #Shear #Peel

No! You risk damaging the wing's surface this way. (OK, you could use a plastic/rubber wedge, but let's try a finesse method first...)
The long clamp squeezes on both ends of the fiberglass part...never touching the wing. This squeeze causes the base of the fiberglass part to bow outwards...shearing along the surface of the wing.
Only light force was applied to tighten the clamp...and the part easily popped off.
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TomKrajci 🇺🇦 🏳️‍🌈 🏳️‍⚧️

Making a custom wingtip wheel for my glider's right wing.

The bottom of the wingtip was covered with clear packing tape, then lightly waxed.

Hot glue temporarily attached the blue Styrofoam mold/form, which also contains the 60mm diameter roller blade wheel.

The part is made from seven plies of 7725 weave fiberglass that will be cut into a triangular shape after wetting with epoxy.

No vacuum bag, so this is a hand lay up. I had to use some small pieces of metal to coax the fiberglass to stay in the correct place.

The garage will be heated overnight so that the part cures, then some tugging and a rubber mallet should separate the part.

#avgeek #aviation #ElectricAircraft #ExperimentalAviation #homebuilt
#Glider #DIY #Wing #Epoxy #Fiberglass #Composite

The underside of the wing tip has been covered in clear packing tape, then waxed.
This is one ply of dry fiberglass, colored white, laying over a piece of green plastic sheet. Faintly visible through the fiberglass is a triangular pattern. After wetting seven plies, I will cut the fabric to that triangular shape. That shape will drape over the form and make the part in one step. The two edges of the open triangle will join and overlap along the trailing edge of the part, aft of the wheel.
Wetted fiberglass has a green tint. Scrap metal helps hold the fabric in the correct location. Strips of light brown fabric are Teflon coated fiberglass, which serves as peel ply. I'm using it to also help coax the fiberglass into the desired shape.
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TomKrajci 🇺🇦 🏳️‍🌈 🏳️‍⚧️

Discovering and fixing a small mechanical interference in the spoilers.

The spoiler cap, in some places, wasn't fitting into the recess in the wing properly.

Why?

1st photo - spoiler is halfway retracted into the wing. One of the parallelogram arms is at a 45 deg angle. You can see that I have already removed some semicircular sections in the upper spoiler paddle to avoid parts colliding as the spoiler closes.

2nd - looking directly up into the spoiler paddle. There are spring loaded bolts to hold the spoiler cap. This particular bolt is rather close to a parallelogram arm...

3rd - ...especially when the arm is swinging more as the spoiler is almost fully closed.

4th - That telltale dimple on the parallelogram arm tells me everything. The bolt is a little bit too long.

A Dremel and cutting wheel removed 2mm of bolt.

Problem solved!

#avgeek #aviation #ElectricAircraft #ExperimentalAviation #homebuilt
#Glider #DIY #Wing #Spoiler #Parallelogram #Geometry #Interference #Dremel

A view of the back side of the upper spoiler paddle (carbon fiber, black) as the spoiler is halfway closed into the wing. One of the grey round steel parallelogram arms has swung to a 45 degree angle. (The arm will swing much further as the spoilers fully close.)
Looking vertically up into the spoiler paddle. One of the spring loaded spoiler cap retaining bolts (shiny, plated metal) is visible. The upper end of the darker gray parallelogram arm is also visible in the right half of the photo. The spoiler is fully open because the parallelogram arm is vertical.
The spoiler is almost fully closed in this closeup view. The gray parallelogram arm has swung through more than 60 degrees from vertical. The arm is getting close to the end of the bolt. (Only the very tip of the bolt is visible from behind the aft lip of the spoiler paddle.)
This dimple in the gray steel parallelogram arm is definitive proof that it is colliding with the bolt. Shortening the bolt solves the problem.
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