How to make compression molded DLG tails

[@TonyPannell]

I absolutely cannot leave this video without telling you that what you did right there was absolutely beautiful to me. If you created this process you did a very great job and I can't see it being more thorough or better in any way. I don't even know what it is you made but I'm about to look it up and I could easily be on board to make and fly one myself. It doesn't sound too far fetched for me, not that I'm looking for any new hobbies but I wasn't necessarily looking for them at the time either. Thanks for posting this! Awesome job.

[@GENcELL2014]

Thanks for making this! Researching and figuring out the process I'll be doing to make a composite electric skateboard deck with a built in space for batteries and electronics. Techniques in this vid are by far some of the best I've seen! I have a ShopSabre 23 cnc router for making the molds and foam core.

[@Julian.Heinrich]

Fantastically done

[@jurijblazin7835]

Nice building video. What is the core material? I believe it is milled as well. How much thinner should be so that fit into the mold with all the fabrics (compared to the mold)?

[@SasquatchComposites]

Core is Rohacell 31 IGF, milled to .015" oversized in thickness

[@jurijblazin7835]

So Rohacell core should be bigger than the mould?

[@SasquatchComposites]

​@@jurijblazin7835 Yup!

[@scottseale]

Thanks for sharing! A dedicated compression mold video would be very interesting. I make diy surf hydrofoil stabilizers using cnc wood core and wet layup. Would love to try a mold process for solid carbon foils and have a few questions. Is that a relief channel at the trailing edge to allow the excess epoxy to escape? Do you have to account for the extra layer thickness where the carbon extends onto the mold surface around the perimeters, i.e when the two halves are clamped up, does that cause a change in total molded thickness which needs to be accounted for when machining the negatives? Thanks again!

[@SasquatchComposites]

The channel allows excess epoxy to escape and also provides a distinct trim line for after demolding. I didn't account for fabric thickness, but my fabric is so thin (20gsm) that it doesn't much matter. If your skins are thicker then I'd expect you'll need to account for that.

[@scottseale]

@@SasquatchComposites Thanks for that information. I recently tried this for a hydrofoil tail wing and was very happy with the results. Nice to have some trailing edge thickness which could then be refined as needed quite easily, and the trim line from the gutter was good reference.

[@NickSmith-hv9zi]

Mind if you provide some info on how you did you build the mold? Is that marble CNCed material? Looks pretty.

[@SasquatchComposites]

It's CNC cut Corian (engineered solid surface countertop). Machines really nicely, polishes easily, and is pretty durable.

[@jurijblazin7835]

I am building hydrofoil wing which will be laminated rohacell foam. CF thickness will be approximately 0.75mm as I will use 4 layers of 160g/m2 CF fabric. How to know how bigger should be the core? Are there any rules? is this like: Core dimensions = final wing dimensions (mold dimension) - CF wall thickness + something which depends of the core material (in your case 0.015")?

[@SasquatchComposites]

I just made mine .015" thicker than the mold. My fabric is maybe .002" thick. For larger parts up to ~.5" thick you can go up to .050" oversize. That'll give you a ballpark place to start, and then you can adjust as necessary if you get areas that don't bond well.

[@SaburoSER]

Awesome video. Which profile do you use for the vertical? Is it symmetrical or not?

[@SasquatchComposites]

Thanks! It's an airfoil I developed myself through a lot of testing, and it's slightly cambered. However, I found that the airfoil isn't nearly as important as the aspect ratio and the weight of the tail.

[@helliontactical5168]

Does the Kevlar hinge ever wear out with continued bending?

[@SasquatchComposites]

It can after a long while. But these hinges generally last the life of the glider for me - several hundred flight hours.

[@magneresjuan]

the PVA comes with the carbowave right?

[@jackelin1981]

Looks awesome.... can you make carbon interior parts for a truck? Specificity, 2015 - 2019 f150. If so I know quite a few who would gladly purchase them from ya, me included

[@magneresjuan]

Great video, how did you got the molds? did you made them? thanks

[@SasquatchComposites]

Thanks! The molds were machined on a 3-axis CNC. The cores were done the same way. That's another how-to video I've got on my list of videos to make.

[@magneresjuan]

I see, here in argentina I thing wont be able to get that 3 axis machine for the molds. Thank you!

[@SasquatchComposites]

I recommend looking into the Millright M3. It's a remarkably capable machine at a much lower price tag than other stuff out there. It'll still be a few hundred dollars with spindle and shipping, but it's the most affordable entry into CNC I've seen. And they do ship internationally. Not sure if that's in your budget, but take a look.

[@magneresjuan]

Thank you !!!!

[@walkertongdee]

Anyone know what cassette tape is? I'm perplexed...

[@SasquatchComposites]

Audio cassette. Predecessor to the CD. Hard to find anymore, but I still see them at thrift stores and garage sales from time to time. Any thin plastic or mylar strip about 1/4" wide would work as an alternative, though.

[@magneresjuan]

nice vid, how did you make the mold?

[@SasquatchComposites]

This mold was CNC machined out of Corian

[@supremefpv7774]

What material and how are your molds made?

[@SasquatchComposites]

These molds are made of Corian solid surface countertop, cut on a CNC. It's one of my favorite mold materials. Machines like butter and polishes really easily. I've only ever found it in 1/2" thick sheets, though.

[@magneresjuan]

excellent video, can you tell me please whats the name of the carbon fabric you use for thids tale? can you send the a web site where I can Buy it ? Thanks

[@SasquatchComposites]

It's Carboweave CW20, available from CN Models cn-models.com/catalog/carboweave

[@Ryzler13]

You might like carbon fibre pinstripe tape.