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- Vacuum bag
- Cut bag in cone shape
- Press vacuum bag firmly on edges to make sure there are no gaps, as this will cause bubbles later
- Use "spear tool" (long, thin rod) to push vacuum bag through mold
- Mold release: use chiseled popsicle sticks and hammer (add more until pops open)
Applying Ablative Coating
- Apply ablative (using layup jig)
- Set up layup jig (looks like a spit with a pole running across it that can be rotated by hand)
- Put old nose cone or some coupler inside the nose cone and put both over the pole. The coupler or whatever you can find to fit inside the nose cone gives you something to grab onto so you can turn it after you apply the ablative.
- Mix 100g Systems 3000 resin + 18g Systems 3000 hardener + 17g phenolic microballoons
- Use heat gun to dry (don't overwork)
Oven Cure
- Oven cure
- Wearing gloves, move the nose cone to the oven.
- Position nose cone carefully such that the surface is not touching the oven, as shown below.
- Follow cure cycle for System 3000 epoxy. The color of the epoxy will change from light brown to dark brown/cherry red, as shown below.
Sanding/Filling in Low Spots
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