I'm keeping with the New Year's traditional saying: Out with the old and In with the new, by tossing out the old plugs that are no longer needed. Tail, nose, and the wheel pant plug are gone, and I'm moving onto the new part of creating the main body molds~! https://flic.kr/p/2kof6kS Out with the old.... … Continue reading New Year 2021- out with the old…
At present I'm working on the left side wheel pant creation. This is the best time to get that done, before I have wheel wells to work around, and before the nose gets cut off. The right side was made previously. I'm also working to prepare the nose-cone molds for use. Wet sanded and polished … Continue reading Preparing the nose cone molds
I finished constructing this tail cone, and removed from the molds a couple days back. There are some spots where the resin stuck to the mold, and it was difficult to get it out of the mold, which means I caused some damage getting it out of the mold. Because I was waiting on 2 … Continue reading Tail cone build, continued
It's exciting to finally be building a piece using the created Zephyr molds! This first piece will be for use in the workshop. I'm also using this build to try out my thoughts on the final lay up. May have to add some here, or less there..... I'm doing the lay-up in a lot of … Continue reading Building up a test tail cone
I finished removing the nose cone mold from the Zephyr plug. I switched back to building the molds using fiberglass mat rather than carbon fiber. I built the tail cone using carbon fiber, and it makes great molds, in terms of very light, and they can look so professional! But it's far too easy to … Continue reading Preparing the nose & tail molds
As I write this, it's mid November 2020, and the country is heading back into a Covid shutdown, voluntary at this point but.... I finished the work on the WAW wheel pants molds, and Dan C did get a chance to test them out a few days ago..... didn't give any appreciable improvements that he … Continue reading Zephyr nose cone molds
One of my first composites projects was trying to make wheel pants for the WAW. The WAW has exposed front wheels for smaller turning radius and easier wheel/suspension maintenance. Wheel pants covering the wheels and wheel well will improve the aerodynamics, but also creates a larger turning radius. On my first attempt I was designing … Continue reading Molds for WAW wheel pants, again.
Once the resin was all set on the lower right side tail mold, it was time to remove the polyethylene walls and the foam blocks, and start preparing to make the lower left mold next. I now realize I used too much hot glue between the foam and the plug... I figured the glue wouldn't … Continue reading Finishing the Tail molds
Progress has been slow but steady, even more so because of my living in a state with a "stay at home" request. Truthfully I'm very much a homebody anyways, but the request meant my career workload was cut down quite a bit, so I have had plenty of time to work on the Zephyr 🙂 … Continue reading The plug is complete!