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| The method used here is a fiber glass
casting. This can be done quickly and cheaply using a
paper cone as a form We start off with a paper cone
We have a handy calclulator for determining the flat
dimensions of a cone template here
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| Tubes of various sizes (even coffee
cans) are attached to help keep the cone in round. Once
the cone was supported to my satisfaction I proceeded to
glass the cone. Before attempting any fiberglassing
project you are advised to read Bradleys primer on the dark art of composites |
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| The actual molding process was too
sticky for any pictures. Here is the finished product
after I had half peeled off the paper cone. Included is a
can of Diet Coke with Lime to provide scale and prove
this is not a retouched polaroid from 1968. Getting the
paper off was quite a chore. I finally resorted to
wallpaper remover |
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| The base of the cone came out badly so
it was necessary to reinforce it with a ring of 10"
tubing. This tube was recovered from a dumpster at work.
It always pays to carefully evaluate what someone else
throws away. (This
fame sponsored by the Cardboard Tube Reclamation Board of
Whapeton, South Dakota)
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| Paper, even poster board makes for a
flimsy mold, and this was no exeception. Plenty of
sanding and filling was required to get the cone
satisfactorly smooth and round |
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| First Coat of spot primer reveals a lot
of blemishes. |
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| A not very inspiring view of the inside
of the nose cone. Is this starting to feel
like your aunt's Betsy's travelogue slide show of her
tour application yarn factories? |
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| Base of the nose cone after the base
plate is glued in. the coupler plate is in the foreground |
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| Eybolt mount prior to gluing to nose
cone. the T-nut thread insert is securely epoxied into
the nose cone |
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| Are we done yet? No! |
More to come
on the nose construction |
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