Weekend @ The Zenith Factory 3

Thumbs up baby!................a great result!

Firstly the new vac bags and pump were amazing and all worked perfectly without fault, the oven was also reliable as ever.

Many thanks to the lovely Mrs Harrison who helped out this evening getting all the moulds out of the oven and bags.

This should be a light one! After looking at the resin scores over the period of the weekend and the two build stages, they look something like this...

Resin/Hardener weighed out = 786g
Resin/Hardener left over from mixes = 194g
Resin/Hardener absorbed in rollers = 177g

Therefore total weight of resin/Hardener used in model = 415g

I will be ordering servos this week ready to mould into the wing when joining together, hopefully the tailplane's will be joined this week and the wings the following week, then it's ready for the next one!

Weekend @ The Zenith Factory 2

Tonight the moulds came out of the oven and bags after the second stage on Sunday. The UHM unidirectional carbon spars laid in, 93g carbon reinforcement and the inside layer of 25g glass cloth. A sheet of peel ply was placed on top of the moulds to soak any excess resin and prepare the surfaces ready for joining together, as when you peel it off (very carefully) when it comes out of the bags it leaves a rough wax free surface to ensure a good bond when joining together.

Also my new fus showing off the colour of my new model.

Weekend @ The Zenith Factory 1

'Big up you all'...............The Chalster looking decidedly pleased as all the bags are sealed by the new vac pump and bags, now ready for the oven.

Also below after the first stage, painted with one outer layer of 25g glass cloth followed by a second layer of 93g carbon cloth at 45 degrees and then the balsa skins.

The bottom picture gives you an indication of how much or little carbon goes into the spars, this UHM unidirectional carbon is 3m by 0.244m and this is all used up!

Progress update

Neil & Mike Just finished for the day in the Northampton Zenith factory. First stage of new wing and tailplane complete, outer skins 25g glass 90g carbon and 1.5mm balsa core now in the vac bag and heating up in the oven. Started at 8:30 finished at 18:00 with no break thanks to the support team (thanks katie) keeping us supplied with tea and bacon butties. Tomorrows jobs are to sand down balsa cores in situ and lay up spar caps and inner 25g glass.

Looking good so far for a light build fingers crossed.

Fus production

Well following a disapionting result from last weekends oven run. I have just opened up the moulds from the last bake and I am happy to say it is the best fus yet! Light strong, as always there is areas for improvement but this is a keeper. Looks like we are on for a sub 2.5kg build.

This my first post from the iPhone hope it works.

Less Hassle Vacuum System

Welcome Back!

After 3 to 4 months of redesigning the workshop to maximise the floor space, building new tables and work benches the new Northant's 'Zenith Factory' is back open ready for business!

I have made a new vacuum pump from an old fridge freezer which is silent running so leaks in the bag can be identified easier, this was trialed this evening with fantastic results.

The moulds sit on the bench on top of a polythene sheet, the breather cloth is then draped over the moulds. Mastic sealant is then piped around the edges of the polythene sheet, this will act as the adhesive and seal for the top layer of vacuum bagging material from R&G.

The air inlet nipple is fixed to the centre of the top vacuum sheet, the whole part of the top bag is then rolled onto a long hollow tube. Starting at one end the top sheet is rolled off, this allows for the perfect alignment with the sealant and a great seal as the top sheet is less likely to 'double over'.

Once in place all that is needed is to press the two surfaces together at the seems, connect the vacuum pump and hey presto!

I was trying to make things easy and after a couple of attempts she works well !

I will set my router up on bench to do them on mass.

I am now getting on with the skins

Still working on SPAR but will keep you posted

Crasher