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PostPosted: Sun 16 Apr 2017 21:45 pm 
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more progress today; All the main shaping of the nose 'plug' is now complete, a fine layer of filler has been applied to act as a grain filler and once set will be rubbed back with 1200 grit silicon carbide paper and sealed with a thinned varnish. The nose cone will then be formed, probably from styrene as it is easy and quick to shape.

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PostPosted: Thu 20 Apr 2017 22:40 pm 
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Final phase of nose master production. Formed the nose cone from Greenstuff® as no milliputt to hand, not sure it will do the job, will it take abrasive shaping? (never used it before) but if not no problem 8-)
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PostPosted: Fri 21 Apr 2017 13:40 pm 
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Fingers crossed on that one . . . .

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PostPosted: Fri 28 Apr 2017 23:10 pm 
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The Greenstuff ® worked out fine. The nosecone is now going through a varnish, rub down, and repeat, cycle to get a reasonable finish. it should be ready for a mould to be taken over the weekend.

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PostPosted: Fri 28 Apr 2017 23:20 pm 
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Excellent news Phil.
I am looking forward to seeing the result as I am sure others will be . . .
Ian

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PostPosted: Sat 29 Apr 2017 07:30 am 
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:cheers:

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PostPosted: Sat 29 Apr 2017 23:25 pm 
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Tonight's progress; varnish rubbed back, further varnish coat applied. It's getting very close now :shock:

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PostPosted: Mon 01 May 2017 22:21 pm 
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Today saw primer applied to standardise the tone so that the shape and texture could be more easily appraised

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Image

There were a few minor blemishes that took a little wipe of filler...

Image

and that WILL be it a couple of coats of varnish, a final polish, and the mould will be made :D

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PostPosted: Tue 02 May 2017 08:39 am 
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Coming along nicely. That nose cone looks fab. :thumb:

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PostPosted: Tue 02 May 2017 09:28 am 
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Thanks BissyB

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PostPosted: Tue 02 May 2017 11:47 am 
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Can I place my order now Phil ? :lol:
So looking forward to seeing it in place . . .
Ian

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PostPosted: Tue 02 May 2017 17:24 pm 
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Right that is it, first of three coats of varnish being applied ready for mould production. :clap:

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PostPosted: Sat 06 May 2017 19:34 pm 
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Today was the day...mould making and casting time. The master was given a final rub and buff using a nail buffer ( you can buy these in bulk on ebay and they are fantastic for the final rubdown and polish of a surface
Image Image

The mould was made from RTV Silicon. I used an addition cure mix as this has a the physical properties this mould needed' particularly that cured rubber is very tough, and that there is minimal, if any, dimensional shrinkage. (a small amount of shrinkage had been allowed for in the master production)

The master was mounted in a foam board mould box. The inside of the mould box was coated with acrylic varnish (stained black to check coverage), the master had been coated in production. The reason for this is that addition cure rubbers can be inhibited by a range of compounds and chemicals, including those found in paper wood and evaporation cure silicon, the acrylic varnish provides an adequate barrier coat.
Image

The silicon was then mixed and before pouring the dust in the mould was blown out with an airline. then a coat of silicon was gently brushed onto the master to ensure a bubble free surface and then poured the rest in as a thin stream, this allows an other significant bubbles to break down. This would be sufficient rather than vacuum degassing the mix (nothing critical in this simple mould).
Image

The mould was filled, ensuring the base was around 5mm thick to give the rigidity required. It was then put aside for 60 minutes to cure
Image

Once cured the mould box and master were removed to leave a mould ready for use
Image

A suitable grade of PU resin was selected and the mould was filled
Image

10 minutes later the finished casting was popped out
Image

The proof of the pudding; while not perfect, it is far more realistic than the conversion kit part, by the time it is faired in and fettled it will look the part I think :?
Image

Now we can push this build forward!!!

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PostPosted: Sat 06 May 2017 22:09 pm 
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Wow brilliant . . .

so looking forward to seeing a decent Lancastrian, keep up the good work Phil.

Ian

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PostPosted: Sun 07 May 2017 21:10 pm 
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With the new nose it was time to start pulling this one together, so the empennage, with horizontal elements from the kit and fin/rudder resin from the conversion kit, was added along with the wings complete with modified engine casings. This is now setting up for continuation over the next few days.
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Image

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PostPosted: Mon 08 May 2017 22:20 pm 
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Great nose. :thumb: You have a bright future in rhino plastic surgery. :joker:

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PostPosted: Mon 08 May 2017 23:01 pm 
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haha thanks Bissy :cheers:

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PostPosted: Fri 12 May 2017 00:04 am 
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Had a chance to pop out and get some more primer today so the Lancastrian was popped into the spray booth and given a light undercoat to look at the nose seam and other worked areas.
Image

Image

Image

Only some minor filling to do around the nose and wing roots, then small parts to add and undercarriage to build

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PostPosted: Fri 12 May 2017 13:00 pm 
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Shaping up nicely Phil. You could have a lucrative career as an aftermarket parts designer. :thumb:

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PostPosted: Fri 12 May 2017 15:38 pm 
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Hahaha, thanks but only when needs must :D

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