REFLECTOR: sanding the cores

Sun Oct 2 20:27:42 CDT 2005

Speaking of the sanding- as everyone knows it is difficult to sand the
cores, because the micro is about 50 times harder to sand than the foam,
so you end up with foam ridges surrounded by low areas of foam no matter
how careful (and I was really careful too, because I was expecting this
problem )- you can try to not run the micro all of the way out to the
surface of the foam while bonding, or as I did on my canard cores (I
learned my lesson from the wings) I used some of the "Great stuff"
canned polyurethane foam as adhesive to put the cores together- you need
to rub them together a bit to de-aerate the foam - the stuff sticks
great, and when it was done, it all sanded like a monolithic slab-
worked great, and no micro to mix either. I have a very fine glue line,
about a 16th or so.  Also did a test piece just to make sure, and the
bond line is stronger than the blue foam.

-----Original Message-----
From: reflector-bounces at tvbf.org [mailto:reflector-bounces at tvbf.org] On
Behalf Of Andy Millin
Sent: Sunday, October 02, 2005 10:31 AM
To: Velocity Aircraft Owners and Builders list
Subject: RE: REFLECTOR: Triax which side is up?

Andy,

You're probably already glassing...  I had wish I could get just 20
minutes with my cores before I glassed them.  They are so easy to sand
when it is just the foam.  I could have save considerable time in the
filling and sanding if I had done a little bit with a long (4' or
longer) sanding block.  I would recommend it if you haven't glassed yet.
Just a 1/16" her and there can save a great deal of time and weight.

FWIW,

Andy
-----Original Message-----
From: reflector-bounces at tvbf.org [mailto:reflector-bounces at tvbf.org]On
Behalf Of Andrew Ellzey
Sent: Sunday, October 02, 2005 10:25 AM
To: Velocity Aircraft Owners and Builders list
Subject: Re: REFLECTOR: Triax which side is up?
That's my plans for today. I have my left wing core ready to glass all
shimmed and true on a true and level 4' X16' table that I built. My
plans are to lay plastic on top of my dry wing, lay out my triax and get
it as perfect as I can before anything has been wet out. I am also am
thinking I will pre cut it somewhat close to size when I am finished and
carefully fold the triax length wise no more than maybe twice and then
lay it on the edge of my table in front of my wing. When this is
complete and I know that I have a full day to start the final glassing,
I then know that I won't be rushed to straighten the squiggles when my
wing is wet. See attached photo.

Andy
----- Original Message ----- 
From: Alex Balic <mailto:alex157 at pwhome.com>  
To: 'Velocity Aircraft <mailto:reflector at tvbf.org>  Owners and Builders
list' 
Sent: Sunday, October 02, 2005 2:31 AM
Subject: RE: REFLECTOR: Triax which side is up?

I'm thinking Alan didn't wan to spend the time to pull them all out- it
is very, very tedious, I did mine all dry- laid the glass on the cores
and pulled with rubber gloves and a set of pliers- you can put a lot of
tension on them, and I had little trouble pulling the slack out- just
took a few hours to do it- I was told that my triax was in "usual"
condition as far as the squiggles are concerned.   As far as if they
matter- yes they do- the triax is designed to be laid so the roving
takes the tension loads of the structure. If the roving is not straight,
then the resin, and the  smaller biax fibers end up doing  this job- as
you can tell, the biax layer is much less substantial then the roving-
in filament winding structures like pressure vessels, the roving is
applied under quite a bit of tension to obtain the proper strength of
the bottle, and the same would apply to our wings- even though the
thickness of the glass on there is quite substantial (can't comment on
the hollow wings since I am unfamiliar with their specific
construction)- 

-----Original Message-----
From: reflector-bounces at tvbf.org [mailto:reflector-bounces at tvbf.org] On
Behalf Of Andrew Ellzey
Sent: Saturday, October 01, 2005 11:44 PM
To: Velocity Aircraft Owners and Builders list
Subject: Re: REFLECTOR: Triax which side is up?

Thanks, to everyone for all the help.

Andy
----- Original Message ----- 
From: Al Gietzen <mailto:ALVentures at cox.net>  
To: 'Velocity Aircraft <mailto:reflector at tvbf.org>  Owners and Builders
list' 
Sent: Saturday, October 01, 2005 6:27 PM
Subject: RE: REFLECTOR: Triax which side is up?

gently pull each strand of the triax to take out any slack and, just
like Alex said below, it adds to the tension and taughtness and forgive
me if I'm wrong he gents, but the strength of the entire wing as well

It does seem that it make for a more rigid wing.  I have to hope it
doesn't matter too much because anywhere I sanded through the primary
and filler on my 'Wingco' wings I saw nothing but squiggles.  Alan
apparently didn't think it was an issue.

Al

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