Part 2 of my attempt to copy my foil front wing. Feel free to comment with questions and if you like my content, subscribe and give this video a thumbs up! Thanks
Hey, about the foam, make your 2 carbon fiber wings parts, trim them and join them with epoxy, make a small hole, like 8-10mm in the mounting point per example and inject through it an epoxy foam (use epoxy foam and not PU, it's dense, lighter, stiffer and stronger for this application), make sure to make a little bit more than needed (to find the volume needed, fill the wing with water, and mesure how much water it contain), the overflow will come out from the hole (direct the wing to put the hole on top and use gravity to make sure the foam fill all the wing. Once cure, the foam will have a good bond to the carbon fiber and be very dense and light. Ps: - use PVA on top of wax to have good release - use a blow torch to remove air-bubble from the wing when you pour the resine - put a box on top of you piece to avoid dust and insect to stick to your resine
U may not achieved the results u wanted now...But u have achieved something much more powerful than everything..The power to believe and go for it. So it´s just a matter of time to get the desired results. Thanks for posting the videos!!
I just finished building my first foil. I used a method similar to hanDIY on RUclips but modeled mine off a flyte 110 classic. Carved the stab, fuselage, and front wing out of plywood using a flapper disk on a grinder. The layers in the plywood make it easy to match each side like a topographic map. I hand laminated mine with carbon fiber, no vacuum bag. It was a huge pain in the butt. I used a trick Clearwater did for his trailing edge though, I put a piece of tape along the underside of the wing creating a 1cmedge for my carbon and epoxy to rest on for the first side. When I flipped it over and trimmed it I had a thin carbon fiber ledge that extended back past the wood creating a good seal. On the leading edge I trimmed the first side down but left 3mm carbon sitting proud of the wood. When I flipped and laid the carbon on the other side it created a good seal. Just required some precision Sandi g to make it nice. I had the same problem with my hot coat. Tonnes of imperfections and little fishes eye holes even after wiping it down with alcohol. It looked ugly as hell, full of imperfections and epoxy runs but before I would spend any more time sanding it I took it out for a test. It worked flawlessly. Going to get some better epoxy and do another hot coat. I could relate to the epic struggle of figuring it all out. I had so many hrs I to my first one it would have made more sense to buy it, but the feeling of riding a foil I made myself was pretty awesome
Thanks for your comment! Quite a nice process you described here. The “figuring it out”, “and the thinking about the next steps” is the best part of a process like this. After you succeed a thoroughly planned experiment the feeling of fulfillment is great!
I’ve been wainting for this one. Thank you so much for showing the whole process and not just the good results. I will try to make mine this summer. You are a king !
To solve the problem of the mounting points because of the eps foam in between, I suggest you core out the mounting points from top to bottom and then fill up with epoxy resin. You then patch it with layers of carbon fiber on the top and bottom.
I was thinking exactly that. Drilling the holes with a much bigger drill bit maybe 16mm. And filling it up with epoxy mixed with chopped up carbon fibre. And 1 square layer of carbon on the top and bottom.
@@Dzjiefoils In the wing I made I just put some wooden blocks in the core at the places where the screws come. Like a diameter of 30mm I think. After that I used big washers when mounting. Works great! But of course a little less aerodynamic with the washers on top of the wing. In your case I think the choped up fibres might work nice. However, I am a bit worried about the stresses directly underneath the head. I do not think the epoxy can handle that, even with the fibers in the epoxy. Also since it is quite difficult to make sure no airbubbles/voids get trapped in the epoxy/fiber mixture. It might be smart to fill up the hole with epoxy and chopped fibers and then just for the last bit of filling the hole, put in a thick aluminium/steel washer with a countersunk hole in it. That way the pressure is distributed better over the epoxy by the washer. You just need a small metal plate that is think enough to make a countersunk hole in. Maybe a scrap piece of steel youve got laying around?
Your approach is similar to the approach taken by clearwaterfoils. According to the owner the method of pouring epoxy for the screws and then reinforcing with fiberglass has lasted years for his wings. He also suggests creating a cover over the fuselage which will distribute loads more evenly such that the screws are only there to ensure the wing doesn't fall off. This method may also improve hydrodynamics over the fuselage.
Thanks for your comment, so just to be clear. You’ve made the outer skins first and then drilled a hole in the piece to fill the empty void inside with Urethane foam?
yes it is ,the injection hole is 10mm ,the air vent hole is 1mm x6places ,, tape the inlet after injection ,,off the tape at the right time after that ,,the urethane will blow out ,,the hole was laminated at the end,,, sorry for my poor english
Did someone also tried to print the inner structure out with a 3d printer (in parts) and use this to put on the carbon? You don't need than to make a mold first. With a very low infill ratio the inner structure will be very light and if needed for parts with a higher infill ration it can also be used to created the parts which needs to be strong. If the 3d printer is too small you can make parts which click to gather to provide one inner structure. Other plus point great designs can then be shared.
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Hey, about the foam, make your 2 carbon fiber wings parts, trim them and join them with epoxy, make a small hole, like 8-10mm in the mounting point per example and inject through it an epoxy foam (use epoxy foam and not PU, it's dense, lighter, stiffer and stronger for this application), make sure to make a little bit more than needed (to find the volume needed, fill the wing with water, and mesure how much water it contain), the overflow will come out from the hole (direct the wing to put the hole on top and use gravity to make sure the foam fill all the wing. Once cure, the foam will have a good bond to the carbon fiber and be very dense and light.
Ps:
- use PVA on top of wax to have good release
- use a blow torch to remove air-bubble from the wing when you pour the resine
- put a box on top of you piece to avoid dust and insect to stick to your resine
Thanks for all the good tips and tricks!
U may not achieved the results u wanted now...But u have achieved something much more powerful than everything..The power to believe and go for it. So it´s just a matter of time to get the desired results. Thanks for posting the videos!!
This is exactly how I look at it. The amount of skills and knowledge I gained is incredible. Thanks for your comment!
I just finished building my first foil. I used a method similar to hanDIY on RUclips but modeled mine off a flyte 110 classic. Carved the stab, fuselage, and front wing out of plywood using a flapper disk on a grinder. The layers in the plywood make it easy to match each side like a topographic map.
I hand laminated mine with carbon fiber, no vacuum bag. It was a huge pain in the butt. I used a trick Clearwater did for his trailing edge though, I put a piece of tape along the underside of the wing creating a 1cmedge for my carbon and epoxy to rest on for the first side. When I flipped it over and trimmed it I had a thin carbon fiber ledge that extended back past the wood creating a good seal. On the leading edge I trimmed the first side down but left 3mm carbon sitting proud of the wood. When I flipped and laid the carbon on the other side it created a good seal. Just required some precision Sandi g to make it nice.
I had the same problem with my hot coat. Tonnes of imperfections and little fishes eye holes even after wiping it down with alcohol. It looked ugly as hell, full of imperfections and epoxy runs but before I would spend any more time sanding it I took it out for a test. It worked flawlessly. Going to get some better epoxy and do another hot coat.
I could relate to the epic struggle of figuring it all out. I had so many hrs I to my first one it would have made more sense to buy it, but the feeling of riding a foil I made myself was pretty awesome
Thanks for your comment! Quite a nice process you described here. The “figuring it out”, “and the thinking about the next steps” is the best part of a process like this. After you succeed a thoroughly planned experiment the feeling of fulfillment is great!
And surfing a thing you made yourself is indeed the best feeling ever!!
Thank you for sharing. Will not even try it now. So much time and work
It can be done a lot faster, but I didn’t know that at the time.
I’ve been wainting for this one. Thank you so much for showing the whole process and not just the good results. I will try to make mine this summer. You are a king !
Thanks for your comment! I’m flattered. Let me know how you get on making your’s.
To solve the problem of the mounting points because of the eps foam in between, I suggest you core out the mounting points from top to bottom and then fill up with epoxy resin. You then patch it with layers of carbon fiber on the top and bottom.
I was thinking exactly that. Drilling the holes with a much bigger drill bit maybe 16mm. And filling it up with epoxy mixed with chopped up carbon fibre. And 1 square layer of carbon on the top and bottom.
@@Dzjiefoils In the wing I made I just put some wooden blocks in the core at the places where the screws come. Like a diameter of 30mm I think. After that I used big washers when mounting. Works great! But of course a little less aerodynamic with the washers on top of the wing.
In your case I think the choped up fibres might work nice. However, I am a bit worried about the stresses directly underneath the head. I do not think the epoxy can handle that, even with the fibers in the epoxy. Also since it is quite difficult to make sure no airbubbles/voids get trapped in the epoxy/fiber mixture. It might be smart to fill up the hole with epoxy and chopped fibers and then just for the last bit of filling the hole, put in a thick aluminium/steel washer with a countersunk hole in it. That way the pressure is distributed better over the epoxy by the washer. You just need a small metal plate that is think enough to make a countersunk hole in. Maybe a scrap piece of steel youve got laying around?
@@Dzjiefoils Anyway, nice project! Good luck finishing it.
Very good plan! I was planning on fixing it this weekend! I let you guys know how it went.
Your approach is similar to the approach taken by clearwaterfoils. According to the owner the method of pouring epoxy for the screws and then reinforcing with fiberglass has lasted years for his wings. He also suggests creating a cover over the fuselage which will distribute loads more evenly such that the screws are only there to ensure the wing doesn't fall off. This method may also improve hydrodynamics over the fuselage.
you worked very hard (^^) i made a hole in the finished product then, urethane(x30) was injected ... its the best movie!!!
from japan
Thanks for your comment, so just to be clear. You’ve made the outer skins first and then drilled a hole in the piece to fill the empty void inside with Urethane foam?
yes it is ,the injection hole is 10mm ,the air vent hole is 1mm x6places ,,
tape the inlet after injection ,,off the tape at the right time after that ,,the urethane will blow out ,,the hole was laminated at the end,,, sorry for my poor english
Thank you for explaining. Your English is not that bad!
Great job!
Thanks!
How about vacuum bagging after PU foam injection? Pour more than required, with pressure it is going to fill very well.
Thats a great idea! If I ever make another one I will definitely try this
whooo excited to see this one! (and sorry for messing up the recording.. woops!
The next one will take half the time!
Yeah!
Did someone also tried to print the inner structure out with a 3d printer (in parts) and use this to put on the carbon? You don't need than to make a mold first. With a very low infill ratio the inner structure will be very light and if needed for parts with a higher infill ration it can also be used to created the parts which needs to be strong. If the 3d printer is too small you can make parts which click to gather to provide one inner structure. Other plus point great designs can then be shared.
Nice thoughts! I don’t have a 3d printer though. Or the skills to use it.
But maybe in the future!
I did it with a resin one ... is not too small.
There is an old fashion way ;) Check out how RC planes wings are made. Styrofoam, NACA profile templates and hot wire.
Could you have used the vacuum to pull the 2 part foam into all the voids?
I think the vacuum just sucks all the liquid foam out of it.
How much cfm is the vacuum pump ?
I don't know. I will try to find out
Where did you get this carbon fiber?
Carbonwinkel.nl
ma non ti conveniva comprare un'altra ala nuova?
I sold my Naish wing and now I only use my home made one!