Building a scale plane

[corsair_pilot]

I'm awaiting some extra funds, but am about to bite the bullet and commit to building an F4 Phantom. It will be powered by a 90mm fan, and will have the all flying tail, flaps, retracts, and I don't think i'll get to the folding wing tips.
It will be modelled on the Aussie ones that were flown down here.
What my real question is, has anyone had much experience building in fibreglass?
Some of the shapes are going to be easier to try and do in glass than doing in balsa, but what i'm having issues with is the plug. Need to know the best way to create said plug. Any ideas?
Oh it's looking to be 55" long

this is what i'm copying

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[Tony]

Wow, I can't help you with your build pal but I do hope you start a new thread on it with pics so we can follow the progress..

[murankar]

I would think using blocks of foam then heat wire the shapes needed. You would also need some templates to use to create the plug sections.

[pvolcko]

I've only ever done some form fit glass work for car stereo speaker pods in kick panel areas.

For a plug, I've usually seen people make styrofoam plugs. Heat wire the big cuts then knife and scrape and sand to final form. Then make the mold from the plug (vacuum plastiforming or done by wrapping in fiberglass). Then make the actual part with the mold.

You may be able to skip the mold making step and just do a half wrap in fiberglass to make your two halves, then bondo and sand to a finished, paintable shell. Making a mold lets you get a clean exterior finish needing mininal finish work.

[danhampson]

I've seen some stills of stuff let mount does (makes rc helis for films like James bond).
He starts by making the basic shape out of blue modeling foam. Them covers in fiberglass to make the mould for the plug.

[Lee]

Thats one of my favourite planes. I have thought of building one for ages.

Here are some pictures from an Edge 540 my friend was building.
Plug was made from plywood shaped on a CNC machine.
He then used filler and sanded it until it was a very smooth finish.
Covered it in releasing agent, and this is what he ended up with.

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[cml001]

A lot of work... A lot!

[Lee]

Yeh, especially when the first plane he built, after a two year process, crashed on the maiden

[danhampson]

Wow I would have probably kicked it up the field.

I found that site http://www.lenmountscalehelicopters.co.uk have a look at the helicopter building tab at the to it will give you an idea of how he does it by hand.

[Lee]

Just had a browse through his site. Wow, theres some nice birds there.

[corsair_pilot]

Thanks guys! I'll check them out. I have a complete set of plans and some drawings n photos of a couple that a guy in the states has made. The plans are for an all balsa version, n the other one is for glass. I just need the push to start the project. Will be posting pics as I go!

[Tony]

That's a good site, clever guy this Len. Got some nice helicopters

[corsair_pilot]

Wow what an awesome site! Was blown away by his 6 month build of that cobra! So much detail so little time!

[Tony]

Did you watch his videos? Awesome

[Giles Darnell]

Tough job to build a plane and really hard to find such a place for scretch buliding material. we have to focus strongly and complete all that need.

[Graham Lawrie]

Very cool:)

[Harper88]

Massive build project. Good Luck.