IV-P Interior Finishing

Submitted by Anonymous on

Forums: 

From: Robert R Pastusek <rpastusek [at] htii.com>
Subject: IV-P Interior Finishing
Date: Wed, 18 Jun 2014 23:15:15 +0000
To: Lancair Mailing List <lml [at] lancaironline.net>

Lancair Builders,



I have a task that's been troubling me for several years now...at least I'm claiming this as the reason for flying, rather than finishing the interior of my airplane!



I am trying to make a "plug" in the shape of the front and back edges of the door frame/fuselage intersection. My intention is to use this to make a fiberglass molding that I can cover with headliner material like I plan for the rest of the fuselage inside top. I have tried to "carve" hard Styrofoam into a shape that will fit the door frame, but it's a three-dimensional curve, and I was not able to produce a satisfactory part from solid foam. I then  tried to use some "weather sealant" spray foam, after taping over the subject area. This was a TOTAL MESS--spray everywhere except where I wanted it. The foam that actually got near the right location dripped off before it became rigid. I have tried modeling clay...way too much required, and too difficult to work with...etc...etc...



Any ideas most appreciated on a way ahead...



Thanks in advance.



Bob

IV-P Interior Finishing

Submitted by Anonymous on

From: F. Barry Knotts <bknotts884 [at] earthlink.net>
Sender: <marv [at] lancaironline.net>
Subject: Re: [LML] IV-P Interior Finishing
Date: Thu, 19 Jun 2014 07:36:45 -0400
To: <lml [at] lancaironline.net>
Message Header


Undecoded Message

Mark Mahnke at RDD rehabed the upper fuselage plug from the original IV-P molds to make a upper fuselage liner for my IV-P.  Covered, it holds the headliner which fits inside the fuse.  Now the headliner comes out as one unit. (Well, two or three pieces, but you get the idea.)  The rehab of the upper fuselage plug was an extra expense to me, but hopefully the plug can now be reused to do make more headliners.  Give Mark a call (541) 504-0305.



Barry Knotts

LIV-Ps, N4XE & N24XE





On 6/18/2014 7:15 PM, Robert R Pastusek wrote:

Lancair Builders,



I have a task that's been troubling me for several years now...at least I'm claiming this as the reason for flying, rather than finishing the interior of my airplane!



I am trying to make a "plug" in the shape of the front and back edges of the door frame/fuselage intersection. My intention is to use this to make a fiberglass molding that I can cover with headliner material like I plan for the rest of the fuselage inside top. I have tried to "carve" hard Styrofoam into a shape that will fit the door frame, but it's a three-dimensional curve, and I was not able to produce a satisfactory part from solid foam. I then  tried to use some "weather sealant" spray foam, after taping over the subject area. This was a TOTAL MESS--spray everywhere except where I wanted it. The foam that actually got near the right location dripped off before it became rigid. I have tried modeling clay...way too much required, and too difficult to work with...etc...etc...



Any ideas most appreciated on a way ahead...



Thanks in advance.



Bob



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IV-P Interior Finishing

Submitted by Anonymous on

From: Mark Sletten <mwsletten [at] gmail.com>
Sender: <marv [at] lancaironline.net>
Subject: Re: [LML] IV-P Interior Finishing
Date: Thu, 19 Jun 2014 07:37:02 -0400
To: <lml [at] lancaironline.net>
Message Header


Undecoded Message
Mold chicken wire to the shape you want, then paper mache over it for rigidity? You can get a fairy smooth finish with paper machce.

A hot wire is a great way to cut foam. Maybe shape the wire to the desired plug shape and cut the foam with it?

--Mark



On Wed, Jun 18, 2014 at 6:15 PM, Robert R Pastusek <rpastusek [at] htii.com

> wrote:

Lancair Builders,



I have a task that's been troubling me for several years now...at least I'm claiming this as the reason for flying, rather than finishing the interior of my airplane!



I am trying to make a "plug" in the shape of the front and back edges of the door frame/fuselage intersection. My intention is to use this to make a fiberglass molding that I can cover with headliner material like I plan for the rest of the fuselage inside top. I have tried to "carve" hard Styrofoam into a shape that will fit the door frame, but it's a three-dimensional curve, and I was not able to produce a satisfactory part from solid foam. I then  tried to use some "weather sealant" spray foam, after taping over the subject area. This was a TOTAL MESS--spray everywhere except where I wanted it. The foam that actually got near the right location dripped off before it became rigid. I have tried modeling clay...way too much required, and too difficult to work with...etc...etc...



Any ideas most appreciated on a way ahead...



Thanks in advance.



Bob



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IV-P Interior Finishing

Submitted by Anonymous on

From: Bill Wade <super_chipmunk [at] roadrunner.com>
Sender: <marv [at] lancaironline.net>
Subject: Re: [LML] IV-P Interior Finishing
Date: Thu, 19 Jun 2014 10:05:23 -0400
To: <lml [at] lancaironline.net>
Message Header


Undecoded Message

Hi Bob-

           You might try pour foam- A/S sells "X-30" liquid foam. Several layers of aluminum foil can be taped in place for a dam. Then the two parts are mixed and either poured or injected into place. It cures in 5-10 minutes so you have to work fast before the mixture starts to expand.



I use a large capacity syringe with a large tip when filling a cavity, using a funnel made of foil to load it. I've found that spray foam will dissolve if it's glassed over- the stuff I use (10-15 years old, label long since gone) will not so it can be used as a base for permanent foam-core structures. In your case, once the plug is shaped I prefer Glad Wrap as a a release covering because it's thin compared to Saran Wrap. The picture shows the wing root TE that I molded on my IV-P.  -Bill Wade



-----Original Message----- From: Robert R Pastusek

Sent: Wednesday, June 18, 2014 7:15 PM

To: Lancair Mailing List

Subject: [LML] IV-P Interior Finishing



Lancair Builders,



I have a task that's been troubling me for several years now...at least I'm claiming this as the reason for flying, rather than finishing the interior of my airplane!



I am trying to make a "plug" in the shape of the front and back edges of the door frame/fuselage intersection. My intention is to use this to make a fiberglass molding that I can cover with headliner material like I plan for the rest of the fuselage inside top. I have tried to "carve" hard Styrofoam into a shape that will fit the door frame, but it's a three-dimensional curve, and I was not able to produce a satisfactory part from solid foam. I then  tried to use some "weather sealant" spray foam, after taping over the subject area. This was a TOTAL MESS--spray everywhere except where I wanted it. The foam that actually got near the right location dripped off before it became rigid. I have tried modeling clay...way too much required, and too difficult to work with...etc...etc...



Any ideas most appreciated on a way ahead...



Thanks in advance.



Bob



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IV-P Interior Finishing

Submitted by Anonymous on

From: Bill Wade <super_chipmunk [at] roadrunner.com>
Sender: <marv [at] lancaironline.net>
Subject: Re: [LML] IV-P Interior Finishing
Date: Thu, 19 Jun 2014 10:05:49 -0400
To: <lml [at] lancaironline.net>
Message Header


Undecoded Message

Some additional thoughts on pour foam:



A little goes a long way- I usually mix 2-3 tablespoons of each part to make a batch. There's no harm in using too little as the stuff is very adhesive and additional pours will bond to cured ones. Poster board is another good dam material.  -Bill Wade



-----Original Message----- From: Robert R Pastusek

Sent: Wednesday, June 18, 2014 7:15 PM

To: Lancair Mailing List

Subject: [LML] IV-P Interior Finishing



Lancair Builders,



I have a task that's been troubling me for several years now...at least I'm claiming this as the reason for flying, rather than finishing the interior of my airplane!



I am trying to make a "plug" in the shape of the front and back edges of the door frame/fuselage intersection. My intention is to use this to make a fiberglass molding that I can cover with headliner material like I plan for the rest of the fuselage inside top. I have tried to "carve" hard Styrofoam into a shape that will fit the door frame, but it's a three-dimensional curve, and I was not able to produce a satisfactory part from solid foam. I then  tried to use some "weather sealant" spray foam, after taping over the subject area. This was a TOTAL MESS--spray everywhere except where I wanted it. The foam that actually got near the right location dripped off before it became rigid. I have tried modeling clay...way too much required, and too difficult to work with...etc...etc...



Any ideas most appreciated on a way ahead...



Thanks in advance.



Bob



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IV-P Interior Finishing

Submitted by Anonymous on

From: Michael Newman <mnewman [at] dragonnorth.com>
Sender: <marv [at] lancaironline.net>
Subject: Re: [LML] Re: IV-P Interior Finishing
Date: Thu, 19 Jun 2014 12:33:19 -0400
To: <lml [at] lancaironline.net>
Message Header


Undecoded Message
You can easily make a pattern at a station by cutting a rough cardboard piece and then using a marker mounted in a block to draw a line on the pattern. Cut the line and you should have an almost perfect fit. Sometimes it takes doing this twice once to get close enough to mark with a smaller marker.

Identify stations that are exactly as far apart as the width of insulation foam. Cut patterns to match each station. Glue the patterns to the foam making a many layered sandwich with the foam extending well beyond the patterns. Use a rasp and then sandpaper to trim the foam to meet the patterns. This should give you a smooth mold.

 Making one part you can lay up right on it and dig out the mold destructively later. If you want to make more than one part cover the mold with some kind of protection (chipped glass, micro, bondo etc.) and mold release and lay up your part on top of it. Depending on how thick your protection layer will be adjust the diameter of the marker to draw the lines a measured distance from the surface you are matching.



On Thu, Jun 19, 2014 at 10:05 AM, Bill Wade <super_chipmunk [at] roadrunner.com

> wrote:

Some additional thoughts on pour foam:



A little goes a long way- I usually mix 2-3 tablespoons of each part to make a batch. There's no harm in using too little as the stuff is very adhesive and additional pours will bond to cured ones. Poster board is another good dam material.  -Bill Wade





-----Original Message----- From: Robert R Pastusek

Sent: Wednesday, June 18, 2014 7:15 PM

To: Lancair Mailing List

Subject: [LML] IV-P Interior Finishing



Lancair Builders,



I have a task that's been troubling me for several years now...at least I'm claiming this as the reason for flying, rather than finishing the interior of my airplane!



I am trying to make a "plug" in the shape of the front and back edges of the door frame/fuselage intersection. My intention is to use this to make a fiberglass molding that I can cover with headliner material like I plan for the rest of the fuselage inside top. I have tried to "carve" hard Styrofoam into a shape that will fit the door frame, but it's a three-dimensional curve, and I was not able to produce a satisfactory part from solid foam. I then  tried to use some "weather sealant" spray foam, after taping over the subject area. This was a TOTAL MESS--spray everywhere except where I wanted it. The foam that actually got near the right location dripped off before it became rigid. I have tried modeling clay...way too much required, and too difficult to work with...etc...etc...



Any ideas most appreciated on a way ahead...



Thanks in advance.



Bob



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IV-P Interior Finishing

Submitted by Anonymous on

From: pete [at] leapfrogventures.com <pete [at] leapfrogventures.com>
Sender: <marv [at] lancaironline.net>
Subject: RE: IV-P Interior Finishing
Date: Thu, 19 Jun 2014 12:33:49 -0400
To: <lml [at] lancaironline.net>
Message Header


Undecoded Message

Bob,



I used the foam that florists use in vases to hold fake flowers in place.  Rigid but easy to carve with coarse sandpaper.  Careful not to put your fingers through it.  In some places around the door I simple glassed over it and left it there.



Pete





-----Original Message-----

From: Robert R Pastusek [rpastusek [at] htii.com (mailto:)

]

Sent: Wednesday, June 18, 2014 4:15 PM

Subject: IV-P Interior Finishing



Lancair Builders,



I have a task that's been troubling me for several years now...at least I'm claiming this as the reason for flying, rather than finishing the interior of my airplane!



I am trying to make a "plug" in the shape of the front and back edges of the door frame/fuselage intersection. My intention is to use this to make a fiberglass molding that I can cover with headliner material like I plan for the rest of the fuselage inside top. I have tried to "carve" hard Styrofoam into a shape that will fit the door frame, but it's a three-dimensional curve, and I was not able to produce a satisfactory part from solid foam. I then  tried to use some "weather sealant" spray foam, after taping over the subject area. This was a TOTAL MESS--spray everywhere except where I wanted it. The foam that actually got near the right location dripped off before it became rigid. I have tried modeling clay...way too much required, and too difficult to work with...etc...etc...



Any ideas most appreciated on a way ahead...



Thanks in advance.



Bob

IV-P Interior Finishing

Submitted by Anonymous on

From: Bill Wade <super_chipmunk [at] roadrunner.com>
Sender: <marv [at] lancaironline.net>
Subject: Re: [LML] IV-P Interior Finishing
Date: Thu, 19 Jun 2014 14:31:53 -0400
To: <lml [at] lancaironline.net>
Message Header


Undecoded Message

 My last message on pour foam- It's been long enough that I forgot the easiest method is to use the disposable icing bags sold by A/S to lay a bead of flox. Double the top to make it stay open, pour the mix in, fold the top over and snip the end as desired.  -Bill Wade