Gap seal foam maker
- planecrazzzy
- Site Admin
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Re: Gap seal foam maker
.
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...
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...
Gotta Fly...
and build your wings on the way down...
Gotta Fly...
- mac
- Seasoned Member
- Posts: 60
- Joined: Sun Jul 29, 2012 7:57 pm
- Location: Grass Valley, CA.
Re: Gap seal foam maker
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.
Looking forward to more discussion on the subject.
Mark M.
N49SS in Phase 2....for good!
N49SS in Phase 2....for good!
- BDA
- Veteran Member
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- Joined: Mon Aug 22, 2016 11:25 am
- Location: Kenai Alaska
Re: Gap seal foam maker
The plates are in the mail
Delivery said Monday
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, Double slotted flaps
Goal: 15mph no wind
N331AK. Shawn Taplin
Wing extensions,Symetrical Airfoil tail ribs (NACA 21)
Mods in progress: Heavier struts, Double slotted flaps
Goal: 15mph no wind
- BDA
- Veteran Member
- Posts: 707
- Joined: Mon Aug 22, 2016 11:25 am
- Location: Kenai Alaska
Re: Gap seal foam maker
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.
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, Double slotted flaps
Goal: 15mph no wind
N331AK. Shawn Taplin
Wing extensions,Symetrical Airfoil tail ribs (NACA 21)
Mods in progress: Heavier struts, Double slotted flaps
Goal: 15mph no wind
- BDA
- Veteran Member
- Posts: 707
- Joined: Mon Aug 22, 2016 11:25 am
- Location: Kenai Alaska
Re: Gap seal foam maker
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, Double slotted flaps
Goal: 15mph no wind
N331AK. Shawn Taplin
Wing extensions,Symetrical Airfoil tail ribs (NACA 21)
Mods in progress: Heavier struts, Double slotted flaps
Goal: 15mph no wind
- BDA
- Veteran Member
- Posts: 707
- Joined: Mon Aug 22, 2016 11:25 am
- Location: Kenai Alaska
Re: Gap seal foam maker
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
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, Double slotted flaps
Goal: 15mph no wind
N331AK. Shawn Taplin
Wing extensions,Symetrical Airfoil tail ribs (NACA 21)
Mods in progress: Heavier struts, Double slotted flaps
Goal: 15mph no wind
- BDA
- Veteran Member
- Posts: 707
- Joined: Mon Aug 22, 2016 11:25 am
- Location: Kenai Alaska
Re: Gap seal foam maker
Few more hours on them, and they havent moved.
Lots of full throttle with takeoffs and landings
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, Double slotted flaps
Goal: 15mph no wind
N331AK. Shawn Taplin
Wing extensions,Symetrical Airfoil tail ribs (NACA 21)
Mods in progress: Heavier struts, Double slotted flaps
Goal: 15mph no wind
- marl59
- Seasoned Member
- Posts: 84
- Joined: Thu Oct 22, 2015 5:59 pm
- Location: Oakland, CA
Re: Gap seal foam maker
Shawn,
Did you notice any performance improvement? Difference?
Did you notice any performance improvement? Difference?
- BDA
- Veteran Member
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- Joined: Mon Aug 22, 2016 11:25 am
- Location: Kenai Alaska
Re: Gap seal foam maker
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.
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, Double slotted flaps
Goal: 15mph no wind
N331AK. Shawn Taplin
Wing extensions,Symetrical Airfoil tail ribs (NACA 21)
Mods in progress: Heavier struts, Double slotted flaps
Goal: 15mph no wind
- BDA
- Veteran Member
- Posts: 707
- Joined: Mon Aug 22, 2016 11:25 am
- Location: Kenai Alaska
Re: Gap seal foam maker
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.
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, Double slotted flaps
Goal: 15mph no wind
N331AK. Shawn Taplin
Wing extensions,Symetrical Airfoil tail ribs (NACA 21)
Mods in progress: Heavier struts, Double slotted flaps
Goal: 15mph no wind
- BDA
- Veteran Member
- Posts: 707
- Joined: Mon Aug 22, 2016 11:25 am
- Location: Kenai Alaska
Re: Gap seal foam maker
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.
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, Double slotted flaps
Goal: 15mph no wind
N331AK. Shawn Taplin
Wing extensions,Symetrical Airfoil tail ribs (NACA 21)
Mods in progress: Heavier struts, Double slotted flaps
Goal: 15mph no wind
- BucF16
- Veteran Member
- Posts: 463
- Joined: Sun Mar 23, 2014 11:47 am
- Location: Alexandria, Ohio
Re: Gap seal foam maker
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
Cheers,
Bruce
Bruce Johnson Highlander # 393
"Because I fly, I envy no man on Earth"
Builder web site:
http://www.bruceshighlander.blogspot.com
"Because I fly, I envy no man on Earth"
Builder web site:
http://www.bruceshighlander.blogspot.com
- SheepdogRD
- Proprietor
- Posts: 933
- Joined: Tue Nov 30, 2010 5:41 pm
- Location: West of Atlanta, GA
Re: Gap seal foam maker
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.
If you used something like the VHB tape, it might have enough thickness to make the seal a bit tighter, too.
Richard Holtz
Highlander N570L -- Ms. Tonka -- in gestation
If just enough is really good, then too much ought to be perfect.
Highlander N570L -- Ms. Tonka -- in gestation
If just enough is really good, then too much ought to be perfect.
- danerazz
- Veteran Member
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- Joined: Tue Aug 18, 2009 9:33 pm
- Location: Bangor
Re: Gap seal foam maker
I was wondering about that, or contact adhesive.
Dane
Paralysis by analysis
#242
Paralysis by analysis
#242
- BDA
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- Joined: Mon Aug 22, 2016 11:25 am
- Location: Kenai Alaska
Re: Gap seal foam maker
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.
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, Double slotted flaps
Goal: 15mph no wind
N331AK. Shawn Taplin
Wing extensions,Symetrical Airfoil tail ribs (NACA 21)
Mods in progress: Heavier struts, Double slotted flaps
Goal: 15mph no wind