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CHUCK'S WEB SITE
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Date: 9-24-2023
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Number of Hours: 1.10
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Manual Reference:
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Brief Description: Producing #d Model Of Lower Cowling
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Over the last couple of weeks I have been trying to figure out the best way to produce a professional appearance to the modification of the lower cowling to eliminate the contact points. I decided to acquire a 3D scanner and a 3D printer to produce digital images and prints for the purpose of designing a new enlarged blister channel for the lower cowling that will provide the required clearance to eliminate the contact points.
The general process will be to produce a 3D scan of the current lower cowling shape with its current blister channel. Then import the mesh into a CAD program (learning Fusion 360 for this part) and lay a surface plane over the current blister channel, matching its shape and contours. Once this is done, the new surface plane can be reshaped to provide a larger blister channel which will allow clearance of the contact points. This newly shaped blister channel will then be output to segmented files that can be 3D printed within the Bambu Lab X1-Carbon's 256 x 256 x 256 mm printable envelope. The components will then be reassemble into the 1:1 sized blister channel form. This form will serve as the "plug" for producing a gelcoat lined fiberglass mold of the new blister channel. With this mold, a new gelcoat blister channel will be produced that can be fiberglassed onto the lower cowling after the original blister channel is cut out. The larger blister channel should provide adequate clearance for the internal components, and eliminate the contact points.
Note that many, many hours have already been, and will continue to be invested in learning 3D scanning operation and techniques, Fusion 360 CAD program operations, and then fiberglass mold making theory and techniques, These hours are not being directly attributed to the Sonex build log. However, the actual plug, mold, and enlarged blister channel production time will be logged against the Sonex build.
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3D scan model of lower cowling produced.
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