Making Your Own Hatches & Doors Page 7
4. Continue to duplicate this process until you have obtained a part thickness appropriate
in strength for your intended purpose. Yes, I know that sounds ambiguous, but you are the only one who can determine the strength and flex attributes of the sandwich. Wipe each sandwich layer with alcohol before applying the next layer of cloth and resin. Epoxy releases waxes when it cures. If this wax is not removed, there will be insufficient bonding of subsequent layers. Copying a second set of template will aid in the final shaping of the parts.

You can clearly see the original template beneath the resin and cloth. It is easy to align the second set of template with those you adhered to the aircraft's surface. You can affix these top template with a single drop of CA adhesive which will be sanded off during the finishing phase. When the top template is affixed, pick the entire finished sandwich from the aircraft surface. note that it has taken the contour of the aircraft's surface. Cut along the template edge with a hobby knife or rotary tool, taking care to
not cut into template shape.

Sand surface of the formed part with 100 grit wet-dry no load sandpaper. Take care to not gouge or scratch the epoxy surface layer to retain a metallic texture for the part. After cleaning with alcohol one last time, blow dry the part. Lay the finished part onto aircraft's surface aligned with the still adhered original template.

With a polymer lead pencil, trace around the finished part's perimeter. Cut out the traced template, including the perimeter line. This provides clearance for the hatch, door or panel. Attach the finished part so it will function appropriately. In the case of the speed brake for the
SU-27, you could control this surface with the throttle, flaps or separately depending on the maneuver combination you plan to utilize a speed brake with. Just the attachment process is another Details article all by itself! Good luck and good flying!
Back To Details Main Page
scalaro2.gif (2313 bytes) '98, '99, Y2K,2005