Sunday, 7 February 2010

Making a new intake scoop

The original intake scoop which form part of the jet unit intake was missing so a new one had to be built from scratch. This was done by cutting a suitably sized steel base plate, and then building up the shape of the scoop with expanding foam filler. The foam was then cut to the required shape and glassed over with several layers of glass fibre.

Expanding foam used to form rough shape of scoop

Mold removed

Cutting leading edges to shape

Shaping the foam

Adding fibrefiller to smooth out the foam

Smoothing out the filler. Starting to take shape

Final stages of fairing

First layer of glass

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