Gap seal foam maker

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Includes: Highlander, Escapade, Summit and SuperSTOL.

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Re: Gap seal foam maker

Postby planecrazzzy » Tue Jun 09, 2020 6:12 am

.
That base plate on your jig looks big enough to clamp an Iron to it...(Close to the cutters )

Then , like the fabric process , dial in the heat needed , and mark it on the Iron .
.
My black and decker iron(18ft cord) has marks that get me close ,
but I still check the temperature each time .
.
JUST a thought
.
Success ....it comes in cans

.
Gotta Fly...
Sometimes you just have to take the leap
and build your wings on the way down...
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Re: Gap seal foam maker

Postby mac » Sat Jun 13, 2020 1:50 pm

A pilot report on how these foam seals work in flight would be very helpful. Please let the group know as soon as you can. While I feel the slow speed elevator authority on my SS is good......more could be better!!

Looking forward to more discussion on the subject.
Mark M.
N49SS in Phase 1
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Re: Gap seal foam maker

Postby BDA » Wed Jun 17, 2020 7:39 pm

The plates are in the mail

Delivery said Monday
SuperStol XL Alaskan With Titan 340
N331AK. Shawn Taplin
Wing extensions,Symetrical Airfoil tail ribs (NACA 21)
Mods in progress: Heavier struts
Goal: 15mph no wind
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Re: Gap seal foam maker

Postby BDA » Thu Jun 18, 2020 9:21 pm

Heat the plate to at least 150* F

I was using a cheapo infra red thermometer

Around 120* it will not cut smooth anymore and the edge will be all raggedy.

The foam should push through easily - but when it is that hot if you pause going through it will leave a step in the foam.

Easier with a helper - just dont torch their arm hair off.

Nice smooth constant push/ or pull

Order enough foam for a couple short practice pieces.
There is a good youtube on it, where they have a piece of wood (doesnt get hot enough to melt the foam) around the hole as the guide.
I did mine without - but I always do things the hard way.
SuperStol XL Alaskan With Titan 340
N331AK. Shawn Taplin
Wing extensions,Symetrical Airfoil tail ribs (NACA 21)
Mods in progress: Heavier struts
Goal: 15mph no wind
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Re: Gap seal foam maker

Postby BDA » Fri Jun 19, 2020 7:52 pm

Foam has not arrived yet so for those waiting for gap seals we are at the mercy of Amazon.
SuperStol XL Alaskan With Titan 340
N331AK. Shawn Taplin
Wing extensions,Symetrical Airfoil tail ribs (NACA 21)
Mods in progress: Heavier struts
Goal: 15mph no wind
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Re: Gap seal foam maker

Postby BDA » Mon Jul 06, 2020 1:07 am

I have been flying the new XL Alaskan with the foam gap seals.

I had 2 pieces per side because of the length of foam that I could get, and the outside pieces blew out on the first flight, but the inside ones have stayed put.

So my friend that has been using them said to spray them with flex seal to make them grippier.

So I gave that a try today. I sprayed them then put them back on the outside (where I assume there is more turbulence).

So far so good, 2 trips around the patch and they are still there.

As for performance difference, it is too early to make a diffinitive statement
SuperStol XL Alaskan With Titan 340
N331AK. Shawn Taplin
Wing extensions,Symetrical Airfoil tail ribs (NACA 21)
Mods in progress: Heavier struts
Goal: 15mph no wind
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Re: Gap seal foam maker

Postby BDA » Tue Jul 07, 2020 9:13 am

Few more hours on them, and they havent moved.

Lots of full throttle with takeoffs and landings
SuperStol XL Alaskan With Titan 340
N331AK. Shawn Taplin
Wing extensions,Symetrical Airfoil tail ribs (NACA 21)
Mods in progress: Heavier struts
Goal: 15mph no wind
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Re: Gap seal foam maker

Postby marl59 » Wed Jul 08, 2020 12:26 pm

Shawn,
Did you notice any performance improvement? Difference?
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Re: Gap seal foam maker

Postby BDA » Wed Jul 08, 2020 11:27 pm

Well
The plane flys better than anything else I have ever flown, including the factory XL and other lightweight SuperStols.

But, I have not flown it back to back with and without yet. So I cannot say for certain.

I had to go back to the far north so wont be able to test for a couple weeks.
SuperStol XL Alaskan With Titan 340
N331AK. Shawn Taplin
Wing extensions,Symetrical Airfoil tail ribs (NACA 21)
Mods in progress: Heavier struts
Goal: 15mph no wind
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Re: Gap seal foam maker

Postby BDA » Sat Jul 25, 2020 4:38 am

So I was working on the plane and took the new longer gap seals out to spray w flex seal and went flying later.

I forgot that I had pulled them out.

As I am trying to rotate at the usual time, I am wondering why I am not flying. Then I come in to land and the tail feels mushy, very concerned at this point.

So I park it, and start looking for the problem ...

I had also noticed my trim acted differently, but ignored it.

Tomorrow I will put them back in and repeat, but I am pretty sure I will not fly without them anymore.

Remember - I have a VERY LARGE airfoil tail - so results may vary.

One of these days, when I have some help I will record numbers.
SuperStol XL Alaskan With Titan 340
N331AK. Shawn Taplin
Wing extensions,Symetrical Airfoil tail ribs (NACA 21)
Mods in progress: Heavier struts
Goal: 15mph no wind
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Re: Gap seal foam maker

Postby BDA » Wed Jul 29, 2020 3:21 am

I did a back to back test today, with and without gap seals.

I flew without them first, 2 take offs and 2 landings.
I could not record distances at the airport.
As on my last flights, the take off was late, rotation at usual time meant draging my tail down the runway.
Landings were fine but when small throttle adjustments were made it just didnt seem to have much effect.

Very curious now if it was the weather or all in my head, I put full length gap seals in, and did a runup to see if they would blow out - HUGE difference in tail force - way more presure on the stick- tail was trying to fly.

So I did 2 take offs and 2 landings.
I just cant explain how much better the tail performs w gap seals.
When I hold my brakes, and power up, I start counting when I let off the brakes, 1 thousand 1, relax back presure on stick, 1 thousand 2, rotate, fly away with a rediculous grin.

The tail with the gap seals feels like it is solid and the aircraft is rotating around the tail.
Without the gap seals, the tail feels mushy and has much less effect on attitude.

Once I get the plane to my home field I will do some actual measurements.

I did have one of them blow out again, so I need to redo my die plates so the foam pieces are thicker, and will stay in.

Those of you that got plates already, I will send you the new version after I test.
SuperStol XL Alaskan With Titan 340
N331AK. Shawn Taplin
Wing extensions,Symetrical Airfoil tail ribs (NACA 21)
Mods in progress: Heavier struts
Goal: 15mph no wind
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Re: Gap seal foam maker

Postby BucF16 » Wed Jul 29, 2020 12:17 pm

Thanks for the update! I’ll be sure to use them. I’m sitting over here in Korea after flying a rare freighter operation. What a hoot to fly without passengers. But I just got a call from Crew tracking that my inbound flight canceled so another 24 hours over here in Inchon. So, plenty of time to plan my final adjustments before I fly.

Cheers,
Bruce
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Re: Gap seal foam maker

Postby SheepdogRD » Thu Jul 30, 2020 9:04 pm

I wonder if some double-sided tape on the leading face of the gap seal would help with retention. Get the gap seal positioned where you want it and then remove the liner...

If you used something like the VHB tape, it might have enough thickness to make the seal a bit tighter, too.
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Re: Gap seal foam maker

Postby danerazz » Thu Jul 30, 2020 10:39 pm

I was wondering about that, or contact adhesive.
Dane

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Re: Gap seal foam maker

Postby BDA » Sat Aug 01, 2020 2:19 am

I made another set today
Above 300* works best
Only do 36” piece at a time so the plate doesnt cool down too much. Below 200* the edges start to get ragged.
Take the cuttings apart immediately, and pick the boogers off.
Then reheat the plate for the next one.

It is important to push the foam through very straight, and not let it rotate.

If you PULL it through it seems to make it narrower.

Use wood pads on the vise jaws so the vise does not pull heat from the plate.
SuperStol XL Alaskan With Titan 340
N331AK. Shawn Taplin
Wing extensions,Symetrical Airfoil tail ribs (NACA 21)
Mods in progress: Heavier struts
Goal: 15mph no wind
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