Springfield Flyer.

[tauruck]

In 88 Brian Kruger was selling all these Allen Key sets. T bars, Screwdriver sets and a multi. I should have bought 5 of each. Bondhus???.
Awesome stuff I keep hidden from the thieves. Peter helped himself to tools and blamed Aubrey the gardener. Then the 250MX bike walked. Aubrey doesn't ride.😂😂😂😂😂😂😂

[floydjer]

Sounds like the type that would drink your last beer and not have money to get more....

[tauruck]

Known the kid since he was 14.
He's Cox 168.5 on my phone contacts.
His dad was driving a 4x4 at 168.5Kph when he got a blowout!!!. Need I say more?.

Stole my brand new airbrush, borrowed my bike to sell for holiday money and more.
Got rid of him.

I had such drama with trying to cut these 4" high density Polystyrene boards.
I made 2 cutting bows. Big ones. One has Nichrome wire and the other has piano wire.
I used Aluminium extrusions left from an abandoned project. The guy walked away never to be seen again.

The bows came out great but powering them was a problem.
I tried a 12v transformer, 2 x 12v car batteries to give 24v, a battery charger and then wasted all my money on a power supply that could adjust amps and volts. NO DICE!.

I call the supplier I got the boards from and he says 500 bucks to slice them into 20mm sheets. I say I have 600 and it's his for his trouble. He played me. No show.
Then I get the idea to cut the boards down the middle of the long side and buy a 3' saw blade and use more Aluminium extrusion for fences so I get even thickness.
The little lady was going out the door to get the 50 buck blade and something just said no.

This guy had given me an inverter that turns 12v into 230 in emergencies. It has a charging function to charge the Lithium battery.
After all I've been through I never had any faith but hey we'll give it a shot right?.

I hooked up a bow and did a test cut. It was pretty slow but it worked.
I used self tapping screws to fasten the guides along the boards. 20mm cuts.
Aubrey had a day off his job so he's in the shop looking for something to do.
He's a cool dude and lives on the property kinda rent free. One day a week to garden or clean my shop.

I tell him my idea. He knows jack and his eyes tell me so. We leaned the board against the bench at about 70*.
I got the wire on the bow right up there on the 8' board against the fences and turned on the power. The guy was giggling like a 5 year old.
It's cutting and cutting!!!!!. I just let gravity do the work. No smoke or red hot wire. It's fairly slow but cut like CNC.

You guys don't know me. I won't give up. Never. Guys talk about hell week. Try 2 months up against 150 guys for 25 spots.

I cut 6 x 20mm and 2 x 40mm sheets in about 2 hours. This is 25D styrene. It's the dense one. They sell aviation spec for professionals at premium and guys use it for bragging rights.

Meet Bo and Jo!!!.😂
2 Blind Faith tools. There's a lot of those in this shop. The Good Lord puts subtle hints in my head daily and they work. I'm a Blessed guy.

[manta22]

Known the kid since he was 14.
He's Cox 168.5 on my phone contacts.
His dad was driving a 4x4 at 168.5Kph when he got a blowout!!!. Need I say more?.

Stole my brand new airbrush, borrowed my bike to sell for holiday money and more.
Got rid of him.

I had such drama with trying to cut these 4" high density Polystyrene boards.
I made 2 cutting bows. Big ones. One has Nichrome wire and the other has piano wire.
I used Aluminium extrusions left from an abandoned project. The guy walked away never to be seen again.

The bows came out great but powering them was a problem.
I tried a 12v transformer, 2 x 12v car batteries to give 24v, a battery charger and then wasted all my money on a power supply that could adjust amps and volts. NO DICE!.

I call the supplier I got the boards from and he says 500 bucks to slice them into 20mm sheets. I say I have 600 and it's his for his trouble. He played me. No show.
Then I get the idea to cut the boards down the middle of the long side and buy a 3' saw blade and use more Aluminium extrusion for fences so I get even thickness.
The little lady was going out the door to get the 50 buck blade and something just said no.

This guy had given me an inverter that turns 12v into 230 in emergencies. It has a charging function to charge the Lithium battery.
After all I've been through I never had any faith but hey we'll give it a shot right?.

I hooked up a bow and did a test cut. It was pretty slow but it worked.
I used self tapping screws to fasten the guides along the boards. 20mm cuts.
Aubrey had a day off his job so he's in the shop looking for something to do.
He's a cool dude and lives on the property kinda rent free. One day a week to garden or clean my shop.

I tell him my idea. He knows jack and his eyes tell me so. We leaned the board against the bench at about 70*.
I got the wire on the bow right up there on the 8' board against the fences and turned on the power. The guy was giggling like a 5 year old.
It's cutting and cutting!!!!!. I just let gravity do the work. No smoke or red hot wire. It's fairly slow but cut like CNC.

You guys don't know me. I won't give up. Never. Guys talk about hell week. Try 2 months up against 150 guys for 25 spots.

I cut 6 x 20mm and 2 x 40mm sheets in about 2 hours. This is 25D styrene. It's the dense one. They sell aviation spec for professionals at premium and guys use it for bragging rights.

Meet Bo and Jo!!!.😂
2 Blind Faith tools. There's a lot of those in this shop. The Good Lord puts subtle hints in my head daily and they work. I'm a Blessed guy.

Once again you have shown that brains, creativity, and perseverance can prevail!

[floydjer]

And he posts about things he has, As opposed to things he had before I was born.

[tauruck]

Known the kid since he was 14.
He's Cox 168.5 on my phone contacts.
His dad was driving a 4x4 at 168.5Kph when he got a blowout!!!. Need I say more?.

Stole my brand new airbrush, borrowed my bike to sell for holiday money and more.
Got rid of him.

I had such drama with trying to cut these 4" high density Polystyrene boards.
I made 2 cutting bows. Big ones. One has Nichrome wire and the other has piano wire.
I used Aluminium extrusions left from an abandoned project. The guy walked away never to be seen again.

The bows came out great but powering them was a problem.
I tried a 12v transformer, 2 x 12v car batteries to give 24v, a battery charger and then wasted all my money on a power supply that could adjust amps and volts. NO DICE!.

I call the supplier I got the boards from and he says 500 bucks to slice them into 20mm sheets. I say I have 600 and it's his for his trouble. He played me. No show.
Then I get the idea to cut the boards down the middle of the long side and buy a 3' saw blade and use more Aluminium extrusion for fences so I get even thickness.
The little lady was going out the door to get the 50 buck blade and something just said no.

This guy had given me an inverter that turns 12v into 230 in emergencies. It has a charging function to charge the Lithium battery.
After all I've been through I never had any faith but hey we'll give it a shot right?.

I hooked up a bow and did a test cut. It was pretty slow but it worked.
I used self tapping screws to fasten the guides along the boards. 20mm cuts.
Aubrey had a day off his job so he's in the shop looking for something to do.
He's a cool dude and lives on the property kinda rent free. One day a week to garden or clean my shop.

I tell him my idea. He knows jack and his eyes tell me so. We leaned the board against the bench at about 70*.
I got the wire on the bow right up there on the 8' board against the fences and turned on the power. The guy was giggling like a 5 year old.
It's cutting and cutting!!!!!. I just let gravity do the work. No smoke or red hot wire. It's fairly slow but cut like CNC.

You guys don't know me. I won't give up. Never. Guys talk about hell week. Try 2 months up against 150 guys for 25 spots.

I cut 6 x 20mm and 2 x 40mm sheets in about 2 hours. This is 25D styrene. It's the dense one. They sell aviation spec for professionals at premium and guys use it for bragging rights.

Meet Bo and Jo!!!.😂
2 Blind Faith tools. There's a lot of those in this shop. The Good Lord puts subtle hints in my head daily and they work. I'm a Blessed guy.

Once again you have shown that brains, creativity, and perseverance can prevail!

Thanks Neil. God Bless you.

[tauruck]

Lollipops!!!.😂😂😂

This is the most hilarious experience of the whole build.

I spent all day yesterday trying to make a Polystyrene cutter for half rounds.
The concept was good but execution poor.
I bent a piece of S Steel tig wire over a tube and gave it two ears to connect the positive and negative 12v leads.
Fed it through a plastic paint roller handle. It looked great and had to work!!!!!. Nada. No heat good enough to cut foam so I hooked it to 24v for effect. I nearly fried the shop.
The plastic coating on the wires caught fire and the stainless melted.

This morning it hits me. Use the router. It's messy but will do the job. No cutters that shape so the brain goes into overdrive.
I used the hole saw to cut a stainless disc and then slotted the disc for an old flapper wheel shaft. I tigged the two together and came up with this Lollipop looking thing.
I sharpened the leading edges on both sides and locked it into the die grinder for a test. BINGO!!!!.😂😂😂😂😂

[tauruck]

I had the amps on the machine too high so I lowered it and welded up a different size.

After the freehand die grinder I did another freehanded with the router.
It turned out great. Tomorrow I can set fences for the router and cut half rounds into my vertical stabilizer halves.
I'll be bonding the steel sleeves with Epoxy to give it the strength it needs.
What a win!!!!!. Thank you Jesus.🙏🏻🙏🏻🙏🏻✝✝✝

[tauruck]

Two different OD tubes because that's all I had for sleeve outers.
This is exactly what I wanted and a wire cutter even at its best can't come close.

[tauruck]

More progress.

These Lollipops work like gang busters.

I've cut the recesses for the vertical stabilizer tubes.
Once bonded and the outer skin covered with fabric I can weld in the male pipes on the chassis where they need to go.

[tauruck]

I made some cutting guides for the profile on the vertical stabilizer from Aluminium.

The cutting bow worked very well. The foam needs to be weighed down for a better cut.

[tauruck]

I found a piece of Carbon/honeycomb panel and cut that to the stabilizer base profile.
It's drilled and fits nice and tight.

The tail halves are bonded and waiting for cure. This will be overnight because it's freezing here.
Got the infra red lamp nearby the part. We'll see.

[tauruck]

We have a vertical stabilizer core.

I've never made a wing using a foam cutting bow so I winged it and got lucky.
This project is particularly significant for a number of reasons.
1st attempt.
The bow was a hit or miss.
The resin system I scored is marked "For Professional Use Only" In almost 40 years working with Epoxies I've never seen this.
Brian from AMT Composites was good enough to sponsor me with this 190 system with a few conditions.
It was redundant stock due to not being able to sell it.
The pros who tried it said it was too temperature sensitive in that it needed too much heat even during mixing.

Here I am in my workshop on the coldest night of the year winging a job that shouldn't work under ideal conditions.
When cutting the profiles from 2" blocks of foam you keep the backing to use for the bonding of the 2 sides.
I'd precut the recesses for the 3 sleeves and had the sleeves cut to size, deburred and surfaces roughed up.
I put one backing down and covered it with some kind of release film I found. I left a lot of overhang because resin has a way of getting into places you don't want.
I laid one profile in there and it located perfectly on the backing despite the film.
The resin was painted on the surface and half rounds filled with resin mixed with Cotton Flocks as a thixotropic agent,filler. The sleeves already blanked off with tape went it
and then some more filler applied to the mating surface on t5he second half.

That went down and self located on the sleeves. I put release film over it and laid the second backing on top.
I spread weights over that, put my infrared heater nearby and prayed.

At 21h00 I was tired of checking the sample piece i left nearest to the heater so I covered the job with a bunch of old curtains, unplugged the heater, locked the shop and went to bed.

This is what I found this morning after removing the backing.

[tauruck]

The resin had cured and the part is solid.
Ready for a little shaping and then a surface skin.

One would say I got lucky again but lucky happens far too often to be that and it's not because I'm good either!.

[tauruck]

I'm ready to start skinning this stabilizer.
Not bad for a 1st attempt at using a backyard cutting bow.
I should play the Lotto!!!.

This piece will get 10 layers o0f fabric after I reshape the top and bottom leading edges.

Things are looking up.👊🏻👊🏻👊🏻👊🏻👊🏻