Grant describes here his complete production process for an F2C Cooling Duct & Wheel Housing being made as part of his 2010 World Championship defence effort..

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The cooling ducts were moulded from carbon fibre as the fuselage is lower beneath the wing than our previous models. This is done to keep part of the wheel inside the fuselage to reduce drag, and elminate the need for a complicated and problematic retract system. To make the manufacture simple the wheel is mounted on the center line of the fuse beneath the air outlet slot. The mounting was incorporated with the cooling duct for strength and simplicity. The complete system was few grams lighter and (after the patterns are made) much simpler to manufacture than balsa cooling and outlet duct and wheel mount. The wheel mounting is stronger. It its very fast and simple to manufacture.

 Click on any picture to see an enlarged view...

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  1. Female Aluminium Patterns were machined the same size and shape as the internal cooling required for the engine. These were done from aluminium for accuracy and because of ease of manufacture.






2. Once used for casting a male pattern in aluminium powder / epoxy resin the female patterns are not used again.



3. Alumium powder and epoxy resin were cast over the machined aluminium female patterns to make a male pattern (as seen in the front of the photo). 80 durometer Poly Urethane pressure patterns (seen at the back of the photo in brown colour) were cast over the male patterns.




4. The carbon used for one side of the cooling duct, 100 gsm carbon cloth cut at 45 degrees bias is laid out on silicone paper ( glad bake). Epoxy resin is added ( LC 3600 )






5. Another layer of silicon paper is put over the top.







6. The epoxy is spread out between the sheets of paper.







7. The cloth is left rich with resin. The excess resin fills the gaps where the cloth can not be pushed over the moulds.








8. 1 Vertical layer of carbon fibre cloth is placed on the pattern.








9. 1 horizontal layer is added, and so on.





10. All the pieces of carbon cloth are shown laid out on the male patterns.

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If you have questions about the construction of these items, feel free to post them under a suitable heading in Australian Control Line Forum, where Grant will endeavour to answer them.

Developed May 2010 by David Kidd.  Your Webmaster is Ron Chernich.