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20041122 - allegro - 08 - tubejigging
20041122-allegro-08-tubejigging: I used a similar method with the tubes. However, the tubes are slightly wider than the top and bottom wedges, so you may want to take your 1/64" thick ply sides and...
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20041122 - allegro - 07 - barjigging
20041122-allegro-07-barjigging: After applying the Cabosil/epoxy slurry (vaseline thickness) to the wedges, and placing them on the bar, I put the assembly between the two blocks and lightly squeezed....
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20041122 - allegro - 06 - barandblocks
20041122-allegro-06-barandblocks: To make sure I was setting up my bars nice and straight, I used a couple of balsa blocks as jigs. On the left, you can see my dry-fitted bar and wedges....
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20041122 - allegro - 05 - titebondedwedges
20041122-allegro-05-titebondedwedges: Another shot of the wedges. I don't know why. 20041122-allegro-05-titebondedwedges: Another shot of the wedges. I don't know why.
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20041122 - allegro - 04 - titebondedwedges
20041122-allegro-04-titebondedwedges: Instead of CA'ing or epoxying the shallow wedges, I used Titebond for the wedges. Titebond is great because A) it's strong, B) you don't need gloves to work with...
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20041122 - allegro - 03 - joinerbits
20041122-allegro-03-joinerbits: All of the joiner parts laid out. 20041122-allegro-03-joinerbits: All of the joiner parts laid out.
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20041122 - allegro - 02 - wallthickness
20041122-allegro-02-wallthickness: Note the wall thickness of 0.015 -- the glass was .003 thick and I did five wraps. Drela says that FG is OK if you don't have Kevlar, and that with 1.7oz Kevlar, you...
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20041122 - allegro - 01 - tubes
20041122-allegro-01-tubes: I did 4 runs of tubes, and my second set came out the lightest and stiffest. On this run I used epoxy with cabosil mixed to somewhere between the "ketchup" and "mayonnaise"...
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20041118 - allegro - 08 - finishedtubes
20041118-allegro-08-finishedtubes: Here are my finished first-run tubes. A couple things I did wrong here: 1. The glass wasn't rolled at 45 degree angle! This increases the strength of the tube...
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20041120 - allegro - 03 - afterrollwrap
20041120-allegro-03-afterrollwrap: After I've wrapped the bars with the wetted fiberglass, I spiral wrap the lay-up using a 1" wide piece of grocery bag in the OPPOSITE direction of the way I rolled...
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20041118 - allegro - 07 - wettingglass
20041118-allegro-07-wettingglass: I used the other joiner bar to figure out just how much glass I'd need to make 5 wraps. Drela sez that the wall thickness of the tubes should come out at 0.015", and...
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20041120 - allegro - 02 - mylarswaxedon
20041120-allegro-02-mylarswaxedon: After "rolling" the mylars onto the bars, I'm ready to wrap the wetted fiberglass onto them. Be careful not to wrink the mylars when rolling....
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20041118 - allegro - 06 - mylarwrapped
20041118-allegro-06-mylarwrapped: The wax will "dry" a little and become tackier, and so then I had the mylar wrapped around the joiner bar. You don't have to be "exact" with the size of the mylar....
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20041120 - allegro - 01 - waxingbar
20041120-allegro-01-waxingbar: Using some 100% caranuba car wax (Turtle brand), I wax the bars to make the mylar stick. Feel free to generously apply, as the mylars don't like to stick to much....
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20041118 - allegro - 05 - alummylar
20041118-allegro-05-alummylar: Okay, so with the wedges curing, I thought I'd take the plunge into making the joiner TUBES. I waxed up the joiner bar itself with some olive oil (I would later switch...
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20041118 - allegro - 04 - sandingshimwedges
20041118-allegro-04-sandingshimwedges: For the three little-tiny wedges for the joiner bar, I just tacked them together with a tiny, tiny drop of CA. Checked their fit on the bar, and then glued...
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20041118 - allegro - 03 - testingwedges2
20041118-allegro-03-testingwedges2: Finally got it sitting flush! I then used some epoxy and glued the wedges together, clamping with little hobby clamps to cure. 20041118-allegro-03-testingwedges2:...
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20041118 - allegro - 02 - testingwedges
20041118-allegro-02-testingwedges: Note that the center wedge in the three-piece wedge block sits out further from the outer two. This is to create an indentation in the wedge block to ensure that we...
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20041118 - allegro - 01 - sightingcfbar
20041118-allegro-01-sightingcfbar: Here, I'm measuring just how high I'd have to make a "pedestal" to check the fit between the CF joiner rod and the plywood wedges. 20041118-allegro-01-sightingcfbar:...
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20041111 - allegro - 27 - tipsfinished
20041111-allegro-27-tipsfinished: After a bit more sanding work and gaping in awe, here they are -- my finished tips. They both weigh in at 12g each, 24g total on my seemingly accurate, but not...
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