making cowls

[Keith Durkin]

At the mo' I am in the process of building an elarged Me 109e, and as there is no off-the shelf cowl available for my project, I am, at some point going to start the process om making my own.
First a few questions.
I have some large blue foam blocks that have to be joined, which would be the best adhesive to use? Ideally I would like to use one that IS NOT instant grab, so I can adjust, to ensure that both halfs are positioned correctly.
I am sure there are several ways to acheive my aim, but an option I am considering, is to mark the outline top/ bottom, and side to side, then cut/sand to the correct shape.Then glass for smooth finish.
Not too sure wether to go for plug and mold, or carve the foam from the inside once I've got a good finish.
I am entering unchartered territory here, so any advice/help would be greatly received .
Keith

[Phil Clark]

One of the foaming polyurethane adhesives (& plenty of clamps) will bond the foam blocks together well Keith........it sands OK so you won't end up with hard lines in the foam as you do if you use epoxy.

Phil

[Keith Durkin]

Many Thanks Phil, will the foaming adhesive give me time to correct if needs be, or is it instant grab?
Keith

[John Greenfield]

Keith

The glue will give you time to position so no problems there.
I would suggest that you cut the foam blocks to profile before gluing and then when you apply the glue stop 1/2 " from the edge so little or no glue actually gets to the edge of the foam. As Phil says it does sand but as you are only using the glue to hold the blocks together it is easier if you do not have to sand the glue.
If you are making a one off and are careful with the layup of the cloth to keep it as even as possible there is no need to go to the trouble of making a mould. Finish off the outside of the cloth layup as well as you can and when cured the outside can be finished off by sanding the high spots and using a fairing compound (available from boat builders) on any rough or low spots. Do this before you dig the foam out from the inside.

Happy building

John

[Keith Durkin]

Thanks for the reply John. The method you describe seems a lot easier than doing the plug/mold route.
The cowl on the Me109e is a very busy part of the plane, so it could be a while before completion of the cowl.

Keith

[stewart clifford]

Hi Keith, what size/scale is the 109

Stewart

[Keith Durkin]

Hi Stewart,
the scale works out to be 1/4.85
This is worked out with my model having a wingspan of 80'' against figures of 32' 4'' obtained from Wings of Fame,- vol.4, which is a journal of classic combat aircraft.

Keith

[Mike Ellis]

It MAY be worth giving Richard Rawle a call. He made a quartrer scale kit of the 109 a few years ago, and I made him the cowl mould for it. Perhaps it would be suitable for your model ?

Mike Ellis LMA 652