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<p class=MsoNormal><span class=EmailStyle19><font size=2 color=navy face=Arial><span
style='font-size:10.0pt;mso-bidi-font-size:12.0pt;font-family:Arial'>Tim unless
absolute lightest weight is a factor a simple balsa-ply laminate as bob
describes works very well, low cost, simple and made from readily available material.<o:p></o:p></span></font></span></p>
<p class=MsoNormal><span class=EmailStyle19><font size=2 color=navy face=Arial><span
style='font-size:10.0pt;mso-bidi-font-size:12.0pt;font-family:Arial'>I first
started doing this 25 years ago usually on large scale airplanes where I wanted
more rigidity and flatness than 1/4" aircraft ply offered as well as a
wider edge for gluing. I've used end grain balsa but feel it isn't worth the
trouble if end grain hard points are inserted where bolts pass through, which
requires a little prior planning. I generally use dowel (poplar if I can find
it) for hard points because it's easy to cut a round hole through the balsa
sheet core with a sharpened brass tube, although spruce block would work as
well. Internal hard points give the blind nut points something to lock into
eliminating the need for an external backer or reinforcement. I believe the
balsa sheet is actually better than an end grain balsa core when thin surface
material is used as it offers better support against dimpling under stress. I
just used slow set epoxy for laminating, clamping the 'sandwich' between two pieces
of 3/4" plywood or weight it down on the workbench.<o:p></o:p></span></font></span></p>
<p class=MsoNormal><span class=EmailStyle19><font size=2 color=navy face=Arial><span
style='font-size:10.0pt;mso-bidi-font-size:12.0pt;font-family:Arial'>I don't
have a paint booth so I still build wood airplanes and use iron on paint.<o:p></o:p></span></font></span></p>
<p class=MsoNormal><span class=EmailStyle19><font size=2 color=navy face=Arial><span
style='font-size:10.0pt;mso-bidi-font-size:12.0pt;font-family:Arial'>Jim Hiller
<o:p></o:p></span></font></span></p>
<p class=MsoNormal><span class=EmailStyle19><font size=2 color=navy face=Arial><span
style='font-size:10.0pt;mso-bidi-font-size:12.0pt;font-family:Arial'><![if !supportEmptyParas]> <![endif]><o:p></o:p></span></font></span></p>
<p class=MsoNormal><span class=EmailStyle19><font size=2 color=navy face=Arial><span
style='font-size:10.0pt;mso-bidi-font-size:12.0pt;font-family:Arial'><![if !supportEmptyParas]> <![endif]><o:p></o:p></span></font></span></p>
<p class=MsoNormal><span class=EmailStyle19><font size=2 color=navy face=Arial><span
style='font-size:10.0pt;mso-bidi-font-size:12.0pt;font-family:Arial'><![if !supportEmptyParas]> <![endif]><o:p></o:p></span></font></span></p>
<p class=MsoNormal style='margin-left:.5in'><font size=2 color=black
face=Tahoma><span style='font-size:10.0pt;font-family:Tahoma;color:black'>-----Original
Message-----<br>
<b><span style='font-weight:bold'>From:</span></b>
nsrca-discussion-bounces@lists.nsrca.org [mailto:nsrca-discussion-bounces@lists.nsrca.org]<b><span
style='font-weight:bold'>On Behalf Of </span></b>Pascoe,Tim [Burlington]<br>
<b><span style='font-weight:bold'>Sent:</span></b> Thursday, January 28, 2010
7:29 AM<br>
<b><span style='font-weight:bold'>To:</span></b> General pattern discussion<br>
<b><span style='font-weight:bold'>Subject:</span></b> [NSRCA-discussion]
Firewall Material</span></font></p>
<p class=MsoNormal style='margin-left:.5in'><font size=3 face="Times New Roman"><span
style='font-size:12.0pt'><![if !supportEmptyParas]> <![endif]><o:p></o:p></span></font></p>
<p class=MsoNormal style='margin-left:.5in'><font size=2 color=black
face=Arial><span style='font-size:10.0pt;font-family:Arial;color:black'>I’m
working on a pair of Genesis’ for next season. In the past, most of my
airplanes have been wood, and while I have some experience with composite
airframes, I’m far from being an expert. I’m ready to put in the firewalls, and
I’d like some suggestions as to what the best material will be for this. I’d
like to keep the weight down (don’t we all), and was wondering if laminated
carbon/balsa panels such as those available at the Composites Store (<a
href="http://www.cstsales.com/carbon_sandwich_panel.html">http://www.cstsales.com/carbon_sandwich_panel.html</a>)
are worth it, difficult to work with, etc. Also, do panels like this
require some special reinforcement where the bolts go through? Special epoxies
for adhering to the fuse, etc.? Or should I just be using aircraft grade
plywood?</span></font><font size=2 color=black face=Arial><span
style='font-size:10.0pt;font-family:Arial;color:black;mso-color-alt:windowtext'><o:p></o:p></span></font></p>
<p class=MsoNormal style='margin-left:.5in'><font size=2 color=black
face=Arial><span style='font-size:10.0pt;font-family:Arial;color:black'> </span></font><font
size=2 color=black face=Arial><span style='font-size:10.0pt;font-family:Arial;
color:black;mso-color-alt:windowtext'><o:p></o:p></span></font></p>
<p class=MsoNormal style='margin-left:.5in'><font size=2 color=black
face=Arial><span style='font-size:10.0pt;font-family:Arial;color:black'>Any
suggestions would be great.</span></font><font size=2 color=black face=Arial><span
style='font-size:10.0pt;font-family:Arial;color:black;mso-color-alt:windowtext'><o:p></o:p></span></font></p>
<p class=MsoNormal style='margin-left:.5in'><font size=2 color=black
face=Arial><span style='font-size:10.0pt;font-family:Arial;color:black'> </span></font><font
size=2 color=black face=Arial><span style='font-size:10.0pt;font-family:Arial;
color:black;mso-color-alt:windowtext'><o:p></o:p></span></font></p>
<p class=MsoNormal style='margin-left:.5in'><font size=3 color=navy
face="Times New Roman"><span style='font-size:12.0pt;color:navy'>Tim Pascoe</span></font><font
color=black><span style='color:black;mso-color-alt:windowtext'><o:p></o:p></span></font></p>
<p class=MsoNormal style='margin-left:.5in'><font size=3 color=black
face="Times New Roman"><span style='font-size:12.0pt;color:black'> </span></font><font
color=black><span style='color:black;mso-color-alt:windowtext'><o:p></o:p></span></font></p>
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