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D.B. SPORT @ SCALE SE5


Don Fry
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The mould, having now been used, benefits from the previous coats of release wax so only 5 coats were applied this time.

 

Here, the second rocker cover is curing while the first one, after 30 hours is now sufficiently hard that it can be cut with a rotary disc. Its been cut right down to be as realistically proud of the cowl as I can make it (without being able to measure the real thing) leaving tabs which, once the cowl has been suitably slotted, will provide a firm fixing.    

 

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The second cover was released from the mould after 18 hours. I'm pleased to say it came away easily which I think shows that the initial coats of wax are still working and so less coats are required for subsequent lay-ups.

 

One unexpected benefit of using 25gm cloth as the base layer was how smooth the surface is. I'd used the fine cloth to ensure that the fairly tight curves were followed without using gelcoat, which I don't seem to be able to master (I'm sure its me as others have success) however, the surface is much smoother than starting out with 50gm cloth, which is what I've done previously when making something with gentle curves like a cowl. I suppose this is an obvious discovery now though its something to remember for future lay-ups.

 

A plus for using fibreglass for this task instead of getting another set of ABS mouldings is the weight, the undamaged ABS moulding weighs 23gm, the fibreglass repalcement, 17gm. Its only a few grammes of course and up at the front end doesn't affect the cg, but an interesting observation that fibreglass can be lighter than ABS.

 

1215576257_NewCowl29.thumb.jpg.e3647decd942d9ac939734d7c2cb5e65.jpg           

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With there being no damage to the exhaust headers and as the whole model is firmly in the ‘sport’ category, the headers were used again in a similar position as before. The exhausts should exit the cylinder heads (if there were any) but these were just put as low down on the rockers as possible.

 

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Having only used a few layers of glass cloth, the walls of the rocker covers came out at 0.5mm thick which provides little support for the exhaust stubs. Small pieces of 1/8” ply were added to support the joints, I thought this prudent as its likely the exhausts could be used as handles when removing the cowl, so didn’t want too much flexing and eventual breaking of the fibreglass bits.

 

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All the main components have been completed now so it’s a waiting game for the weather to improve to get on with painting.         

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  • 4 weeks later...

After a protracted wait, the weather eventually decided to cooperate in providing suitable painting conditions.

 

The cowl was given a couple of coats of 2K primer, rubbed down and then KlassKote colour applied. The colour had been mixed from other standard tins, fortunately some of the paint from the earlier restoration had been saved . The difficult bit was mixing the (Part B) catalyst so that the dried paint had the same sheen as the rest of the model - I wish I had written down what I did earlier. After 4 attempts (and 3 rubdowns) this will have to be near enough.

 

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The radiator shutters, rockers and exhaust should be easier as there isn’t a requirement for matching.

 

Everything will be in 2K paint to resist glow fuel attack.     

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Well chaps, as much as I don’t like repairing, the earlier damage didn’t warrant discarding of the model so thought it best to try and do an acceptable job prior to selling. Selling has been the intention for some time as it takes up valuable space. Over the years the model has been flown intermittently – I’d rig it, fly it and enjoy the ease and grace but because, once rigged, it’s the only model I can get in the van and then occupy a lot of space in the shed, it’s had an alternating frequent flyer, hangar queen, type of life.

The model is over 25 years old, one of the earlier one-piece wing types. Eddie Stoker, when he bought the company recognised that being able to break down the model into smaller, easier to rig pieces was the future, but this one pre-dates that. It also has Mick Reeves (handed) flat wire rigging, which improves the structural strength so will withstand quite high G forces, not that’s what the model was intended for, this though only adds to the rigging time.

Do you think a bit of weathering or patina would look more realistic – it is only a sport model after all?         

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The extra bits have now been painted and attached to the cowl.

 

384822126_NewCowl33.thumb.jpg.12eca4ceb8d70248ea6a44f1ff651b4c.jpg

 

This is as far as I can get until the engine has been returned from repair. With the uncertainty about how long it would be to get a replacement crankcase, if there was one of the imperial thread type to be found during the Laser Engines clear out, the decision was taken to get one of the experienced LMA machinists to clean up the damaged front face and, if necessary, fit a shim to make good again. Should a replacement crankcase eventually be found, it could still be used.

 

The model will now gather dust again for a while but with the weather now more suitable for painting its on with the next project...........      

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  • 2 weeks later...

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