Pictures of the Week                                              July 6, 2002

(Click on this thumbnail for a full sized picture)

This is a picture of the  mold that I built to make a foam plug from Insta-Foam for the lower cowl cooling inlet.  As it turns out, I didn't mix enough foam the first time around and the mold is only about 90% full.  The foam came with no instructions so now I've got to find out how long to let this first batch cure before I mix up the other 10% of the foam and pour it into the mold.  Ultimately, this will be a 12 degree conical duct to slow down the cooling air for the turbo inter-cooler and oil-cooler.

KRnet came to the rescue with the info I needed (thanks Mark) now it's on to the next step.  The duct mold is complete.  Now I'll wrap it with duct tape and glass it. 

Next step was taping the mold with duct tape (black here) and cutting out a paper pattern to use to cut two layers of fiberglass for the duct. 

Time to mix some Aeropoxy and get on with it but I'm taking a moment to "measure twice, mix once"!  The epoxy will flow tonight

Here's what the mold looks like with two layers of glass epoxied on

                                                                                                    July 10, 2002

And here's what the finished product looks like popped off the mold.  The long metal strap in the foreground is what I used to slide between the mold and duct and pop it loose.  It took some effort to work it around the duct and break it free from the mold, but both the duct and the mold survived.

                                                                                          July 11, 2002

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