My Rebuild

[Caflyt]

Thought I'd start a new thread to update those who are interested.
I'm testing out a process of cutting shaping and painting extruded polystyrene foam board to make my interior. I hope to give more info on my process as I figure it out but tonight I'll show you guys my test piece....Captain side window. After cutting pieces and blocking out the rough shape I sanded and shaped them into the window frame. Then I covered it with some stuff called "Mod Podge" to seal the foam in preparation for primer. Then I primed it and sanded it lightly. What you see here is the result so far. After painting I will coat the entire creation with polyeurethane to add more stiffness and impact resistance.
I will add some more pics this weekend showing a little more of how I got to this point but for the sake of brevity, I will leave you with my latest milestone.

Thanks!!
Craig

[mickc]

Looks great Craig!

[geeman47]

Very nice, and thanks for the play-by-play.  I'm interested in learning your techniques. 

George

[wildcat02]

Hi Craig,

Very nice !

I also use a technique like you (with foam and polyester).

http://www.flightdeck737.be/hardware/platform/window-liners/

[Caflyt]

Clement,
I have seen your site before, your stuff is amazing!
I don't recall seeing your page on the foam technique but wish I had before I started this. I think the only difference is the polyester epoxy step. I have been shaping the pieces "in place" and I find it to be best for me. I threw a coat of paint on it today and will soon finish with polyeurethane.
I will likely be picking your brain in the future if that's ok?

Craig

[Trevor Hale]

Someone call Boeing QUICK. Someone stole a window frame!  Lol. Wow!

[Caflyt]

Ok,
I covered it with polyeurethane and it is looking good.
The sim is a mess but starting to take shape!!
Exciting!!

[wildcat02]

 

[mickc]

Looks great Craig

Those window frames can be a real "female dog" to get right, and you've nailed it!

[Caflyt]

Thanks Mick,
Now the challenge will be getting the other side to look the same!!
Maybe I should have made "half-a-sim" 
Thank you guys for all of the encouragement, it really helps.

George,
Take a look at Clement's site, it's much more instructional than I could be.
http://www.flightdeck737.be/hardware/platform/window-liners/


Craig

[Caflyt]

I got a little bit more done on the captain side side wall this weekend.
Just a couple of updated pics. Enjoy.

Craig

[mickc]

Nice work mate,

Interesting use of a motherboard box for the rudder pedal support ...   

[Caflyt]

Mickc
That was a "first attempt" at the rudder pedal unit. It is no where near completion though. It was abandoned for time on other things. I will get back to completing them one day.

OH WAIT!!
I just got the joke!!
I'm a little slow tonight

I just noticed the box you were referring to!

[Aerosim Solutions]

That's a great idea and good timing for me as the window frames are the next job on my list. I have a sheet of 20mm molding foam, I might drag that out for a play on the weekend!!

Cheers Gwyn

[tennyson]

There is also another technique which I have used extensively with my build.
I use 3mm MDF and then cover in cloth and fibreglass resin.

I made both of my sidewall panels (thanx to the generous donation of plans by Vidar) from this method and it's great for box section stuff.

I just did my pedestal the same way and am sanding and filling this afternoon.

It does make the unit very strong, with the fibreglass, as the MDF on it's own is too weak and flimsy.




Frank Cooper

[Caflyt]

I can't wait to see what you come up with Gwyn as I'm always inspired by your work!
I only use the foam for things like the trim which need to be "shaped" and then MDF for the other pieces.

Frank, I will be watching your pedestal build closely as that is soon to be on my list.
I plan on covering the entire foam sections with epoxy resin for strength.

Craig

[Trevor Hale]

I would be concerned the epoxy would eat and deform the foam wouldn't it? That would be my concern. I have to create an extension off my TQ for a pedestal, and would like to try one of these methods.

Trev

[Caflyt]

Trevor,
This foam is very similar to the foam we used to make surfboards when I was young. We shaped it then fiberglassed it. However, this EPS or Extruded Polystyrene foam is a little different so it will take some testing to figure out the best way forward. I've spoken to a tech guy for US Composites   http://www.uscomposites.com/epoxy.html   
here in Florida and he said it should be fine as long as I use the right hardener to slow the cure time down. If it is too strong the resin quickly heats up and will damage the shape and possibly the foam itself. He recommended I mix the resin in small batches for 6 to 7 min then pour it into a paint pan so it is a thin layer which cools the mixture and prolongs the activation time of the mixture. Then I will "wet" the piece and lay on lightweight fiberglass cloth and then re-wet the cloth using a specialized roller for resins.
I will test the process and report as soon as I can.
I "sealed" the foam with some stuff called Mod Podge which protected it for painting so that may help buffer the effects of the resin on the foam.

Guys....meet your new  Guinea Pig !?!?

I ain't skeeerred 

[tennyson]

Yeah, Craig's right, the foam you use for fibreglassing is resin resistant.

I'm at the end of my build and really thought long and hard about building the pedestal, as there are many pre-built ones on the market that are top notch.

Only problem is, by the time you pay for freight and the old customs and tax, you are looking at well over 1000 bucks.
To me, that is ridiculous. So, I got scroogey and built it myself.

I'm really happy with the finish now, another fill and sand and then I'll be putting undercoat and paint on it, so I will have it in the sim by week's end.

I enjoy working with my hands and enjoyed this little project. I don't like working with fibreglass and especially the sanding part, but it was just one item, so I made the exception.
My pedestal bay has been made to fit the simworld frame, which I have altered to accommodate a full set of CP Flight radio's  and fire handles, so it's all top of the wazza gear inside.

I'll throw up another pic of the finished item, when it's done.


Frank Cooper

[Caflyt]

I think I am going to scrap the Epoxy resin idea. I have found an alternative that seems to be just perfect. It is called styrospray and it is specifically made for this application.

http://www.industrialpolymers.com/product-list/styrospray-product-list/styrospray/

They are sending me a sample of their product this week and I will evaluate it. It looks like it's exactly what we would need. It is easy to apply using a roller or brush. I spoke with the guy that I met who makes these foam pieces for amusement parks etc. and he thinks this product will work great.
Another great thing....it is inexpensive. 2 quarts which covers 25 ft.² with three coats is only $33 US.
I began to get a little worried about using the resin as it might deform the foam or could eat into it even with protection.

I will update you guys as soon as I have tried it.

[tennyson]

Wow, Craig, I took a good long look at that web site and the face of glassing has certainly changed.
I was worried about the cost, but as you've said, it's reasonably priced.

It's got to be the way of the future and one that many cockpit builders should be looking at for making products that need a fibreglass finish.



Frank Cooper

[Caflyt]

I received two samples of the Styrospray this week, one is foam covered with the brushed on coating and the other was wood. The coating is quite durable and seems to be a perfect product for my project.
I am ordering the 2-quart supply today for $33.00 + shipping.
Once it arrives, I will start to test it in my build and report back.

[Trevor Hale]

I can't believe the shine you get off that stuff..  Wow, I happen to think it isn't cheap either LOL.  Looks awesome.

[geeman47]

That is some awesome stuff it appears.  I used to live about 30 miles from them.  Now it's closer to 530 LOL.  I will be waiting on your reports because it looks like the stuff to use for my partial interior liner I'd like to build.

[tennyson]

Gee, that looks good. I was thinking also, that it might be just the stuff for producing liners.

On my end, my pedestal was sanded and filled about 1000 times and I achieved a nice result.
From there, I painted it and then finished with a low sheen clear gloss.

I also made the surround from Perspex and painted and fitted, as well.

So, after saving the money for a pedestal, I installed the full CP Flight suite into it....hahaha, 6 or 7 grand's worth of radio's, including the CP Flight fire handles!

Anyway, I'm super happy with the result.(below)





Now, it's on to my J-rails and fitting my seats,



Frank Cooper