Here are some pics of my completed (but rough) cockpit moldings. Although I had the overhead Aircraft panels I did not have the side window frames or sidewall attachments and therefore had to make them from scratch.
All the 'white' moldings are constructed from 3/8" foam board. The material is easy to work with and is glued using 'weldbond' glue that dries clear and forms an extremely strong bond.
I developed a technique using Elmers wood filler to hide any seams that would normally appear when two pieces are attached (glued) together as in the window beam posts etc.
In the past I used to cut a 1 inch strip of heavy paper, then fold it in half to form a protective edge which i would then glue (not weldbond, but something else) onto the 90 degree corner...but found after some time the paper would open up along the edge.
Any product the foamboard that remains 'wet' for any period of time will cause the boards waxy paper coating to 'bubble' up and deform.
Using elmers wood filler, you and eliminate any imperfections and can even sand it down to form a perfect finish This is due to the fact that the wood filler dries very quickly and does not have time to do any damage to the finished product.
I then prime the product with Krylon fast drying paint, and then use a flat white spray finish to complete the product.
When a curved surface is required like the left and right approach plate holders...all I do is take a srtip of foam board, and cut tiny vertical slits, spaced 1/16th inch apart, in the material so I can 'curve' it into place....the amount of cuts depends on the radius of the curve.
I then glue it into place and when dry use wood filler to fill in the cuts...sand...prime..paint...
In fact if you look very closely at the Captains and First officers approach plate holders coming off the left and right sidewalls...you can see the brown wood filler on the curved portion. (Not been finished yet).
When the moldings are being 'fitted' I use 3m green masking tape...any other type will rip the paper from the foam board when removed...this green tape does not damage the finish.
Really impressive, love seeing some great projects like this emerging.
Rhys b
Very nice job. I can't wait to see more on this thread!
I am still trying to figure out what foam board is... I just to picture it. Anyone know if it is available in Germany, particularly in the Stuttgart area?
Warren
Warren,
we can buy it here in Canada so I am sure you can get it there. Ordering online is another option.
Foam board is nothing more than a core of dense foam sandwiched with thick waxy paper;
Tried to download an image here, but the address is too long.....
Hello Warren,
It might be PVC Foam Board or a type of HDPE board. I looked into this some time ago and there is a large variety of board material but all with different mechanical and chemical properties. Depending on the type it may bend easy or needs to be cut at the back. Some types will take glue well while others can only be welded. There is also a type of Aluminum/Polystyrene foam board that has great properties but may be hard to get. Some of the board types are also quite expensive (>€100/m2)
Hope this helps,
Best Regards,
Marc
Thanks guys.
I'm aware of the PVC foam board. I've used it before but I haven't seen anything like that at the Obi, Hornbach's, and Baumarts I've been to. I'll keep my eye out, I guess
Hello Warren,
I do not think that the typical DIY stores will have these supplies, at least, they do not in the Netherlands.
Only option here is to find specialty companies or webshops that are willing to sell to private persons.
I guess it will be the same in Germany.
Best regards,
Marc
Quote from: fsaviator on December 16, 2013, 05:27:13 AM
Thanks guys.
I'm aware of the PVC foam board. I've used it before but I haven't seen anything like that at the Obi, Hornbach's, and Baumarts I've been to. I'll keep my eye out, I guess
Just looked on Bauhaus' back office and they have it listed as a stock line. Might want to try there? Also try the heavier merchants.
Thanks Rhys. Was that German? What's it called in German? I'll Bauhaus Thursday as it's near where I'll be
Warren
Quote from: Mach7 on December 16, 2013, 04:11:58 AM
Warren,
we can buy it here in Canada so I am sure you can get it there. Ordering online is another option.
Foam board is nothing more than a core of dense foam sandwiched with thick waxy paper;
Tried to download an image here, but the address is too long.....
Now I'm tracking. Same stuff I used in framing class years ago.