I'm just starting on ideas for a hand built cowling for my plans built ultralight aircraft. This video sets up a great foundation for my cowling build. Thanks.
That was gonna be my last resort for sure. I wanted to keep it one piece for now for a couple reason if at all possible. More to come later on those reasons👍
I think if you would have paid an engineer to create a plug for a negative mold and the vacuum bagged the final cowling you would have had very similar results.
Excellent job Josh..and yes its very frustrating when your trying to demold a difficult part...just been through that myself modifiying a savannah cowl
I’m about to make substantial changes to an existing cowl set, due to upgrading a 4-cylinder engine to 6. I’ll be using techniques I’ve seen you (and others) demonstrate. If I didn’t miss something, so far your layer schedule includes 2 layers of bidirectional fiberglass and 2 layers of carbon fiber. Since I’m certain you have thoroughly researched this project, what fabric weights were these and what will be going over top of them? If you don’t have time to answer, I completely understand. Thank you for sharing what you do. Every task you do, seems well beyond the results of most third timers.
The weight of the carbon is 5.8oz 3k weave. It’s a bit lighter weight than I had planned to use but it was a good price. You do have the layer count correct and I plan to add another layer of carbon on the exterior surface. Any additional strengthening will happen on the inside. I had all the other fabrics from previous projects so I don’t remember the weights but it was similar to the carbon (maybe a little heavier).. my plan is to use an automotive clear over the carbon since I want some portion of it exposed. The rest will get vinyl wrapped when the plane gets covered later. Thanks for watching and engaging sir!
@@Project2Aero I appreciate you sharing these details. I have similarly made materials choices, influenced greatly by what I have on hand, many times 😀
1. I think lots of people use clear package tape as a mold release. 2. Do you plan to split the cowling into 2 halves? 3. How did you get the glass/carbon to stick to the underside without it falling off during the cure?
I considered the tape method but couldn’t get it to conform very well to the compound curves. I do split the cowl and you’ll see it in one of the other cowl videos that’s already released as well. The underside was tricky and I ended up finishing that part after pulling the cowl off the mold.
I have used epoxy primer first then PVA as a release but just as you had problems removing it it was a chore with my method also but not quite as hard as yours. Thanks for the video great job probably the way to go I am still waiting on my Titan 1 year and 8 months now
@@Project2Aero I do think removal would have been much easier with mold release. But since you might be adding reinforcement layers inside, you’ll be glad you didn’t use it. I’m making an oil pan cooling plenum for a Gen-4 Jabiru 3300. Because it has multiple compound angles, the mold process I came up with (as a novice), requires mold release wax but also that I add additional layers of glass after initial demolding. I clean it with acetone, using scotchbrite pads and cloth but I suspect subsequent layer bond is compromised, to some degree. Not critical in my case. But You’ll be confident bond for your additional layers is optimal for your method, it seems to me.
I'm just starting on ideas for a hand built cowling for my plans built ultralight aircraft. This video sets up a great foundation for my cowling build. Thanks.
Thanks for watching! It worked out great for me!
Job bloody well done
Thanks!
Awesome Job!!!
Thanks!
Good job. Watching your videos and learning. I will be starting my cowl this winter. Thanks
Been a fun project so far! Thanks for watching👍
Looks really nice!
Very nice!
Thanks!
That's awesome!
Thanks!
Beautiful work
Thanks!
That turned out amazing. Thanks for the "in depth and in detail" cowling build. I would say the prop sits just right.
Thanks Doc🤷🏻♂️
nice work! saran wrap isn't a bad approach but coating it with a release agent would have helped when pulling it off
Thanks!
Looks amazing! I am toying with the idea of doing this for my BH build.
Custom cowlings are challenging. You are doing an excellent job!
Thanks! Y’all will have to school me up some day when I can make it out your way👍
Done is better than perfect!?!? Looks great 👍 press on and let’s race. 😉😎
Before removal,I would have made the cuts to separate the upper from the lower cowlings, then removed as 2 separate pieces.
That was gonna be my last resort for sure. I wanted to keep it one piece for now for a couple reason if at all possible. More to come later on those reasons👍
Fantastic, that is some significant effort.
Thanks!
I see that you hired another guy to help you... Oh. Wait. 😆 The time you spent fabricating the cowl was well worth it. It looks great!
Lol, glad someone caught that! It’s cheaper to duplicate myself
Awesome job Josh!! That cowl is going to look awesome. Fitment of the spinner is spot on.
Thanks!
spectacular results for not having glass experience!!! Hope you enjoyed the journey enough to WANT to do more...
Thanks! I’ve got plenty more to do before I’m done with this build. It’s been fun so far🤷🏻♂️
great video. I know the videos are a second project when you are building. they are appreciated. thanks for the ideas and entertainment they provide.
You are very welcome, thanks!
Looking great Josh! Hours of labour intensive work right there, great job!
Thanks man👍
I think it turned out great. I've watched all of your videos and this one is very good! PS, your boy is growing fast!
Thanks Mike! The little guy ain’t so little any more🤷🏻♂️
Beautiful work! Nice job on the shape!
Thanks!
That looks great, hopefully I will be diving into mine shortly. Keep up the good work. 👍🏼
Thanks!
I think if you would have paid an engineer to create a plug for a negative mold and the vacuum bagged the final cowling you would have had very similar results.
I’m pretty happy with the results for sure. Not a ton invested and it really didn’t fight that much👍
Excellent job Josh..and yes its very frustrating when your trying to demold a difficult part...just been through that myself modifiying a savannah cowl
Thanks Mark! Sure was a relief to get it finally… it’s been an adventure for sure👍
Very cool! Making progress!
Thanks!
I’m about to make substantial changes to an existing cowl set, due to upgrading a 4-cylinder engine to 6. I’ll be using techniques I’ve seen you (and others) demonstrate. If I didn’t miss something, so far your layer schedule includes 2 layers of bidirectional fiberglass and 2 layers of carbon fiber. Since I’m certain you have thoroughly researched this project, what fabric weights were these and what will be going over top of them?
If you don’t have time to answer, I completely understand.
Thank you for sharing what you do.
Every task you do, seems well beyond the results of most third timers.
The weight of the carbon is 5.8oz 3k weave. It’s a bit lighter weight than I had planned to use but it was a good price. You do have the layer count correct and I plan to add another layer of carbon on the exterior surface. Any additional strengthening will happen on the inside. I had all the other fabrics from previous projects so I don’t remember the weights but it was similar to the carbon (maybe a little heavier).. my plan is to use an automotive clear over the carbon since I want some portion of it exposed. The rest will get vinyl wrapped when the plane gets covered later. Thanks for watching and engaging sir!
@@Project2Aero I appreciate you sharing these details. I have similarly made materials choices, influenced greatly by what I have on hand, many times 😀
1. I think lots of people use clear package tape as a mold release.
2. Do you plan to split the cowling into 2 halves?
3. How did you get the glass/carbon to stick to the underside without it falling off during the cure?
I considered the tape method but couldn’t get it to conform very well to the compound curves. I do split the cowl and you’ll see it in one of the other cowl videos that’s already released as well. The underside was tricky and I ended up finishing that part after pulling the cowl off the mold.
I have used epoxy primer first then PVA as a release but just as you had problems removing it it was a chore with my method also but not quite as hard as yours. Thanks for the video great job probably the way to go I am still waiting on my Titan 1 year and 8 months now
Surely you mr gettin close to gettin a motor!! That wait time is crazy
I just watched this (and Part 1) a third time… did you apply mold release wax over the plastic wrap?
No sir I didn’t. Would have been a good idea I think👍
@@Project2Aero I do think removal would have been much easier with mold release. But since you might be adding reinforcement layers inside, you’ll be glad you didn’t use it.
I’m making an oil pan cooling plenum for a Gen-4 Jabiru 3300. Because it has multiple compound angles, the mold process I came up with (as a novice), requires mold release wax but also that I add additional layers of glass after initial demolding. I clean it with acetone, using scotchbrite pads and cloth but I suspect subsequent layer bond is compromised, to some degree. Not critical in my case. But You’ll be confident bond for your additional layers is optimal for your method, it seems to me.
@@foesfly3047 that’s a very good point! I never even considered that. Your project sounds cool!