Test Fin Can Procedure
Required Materials
Raw Materials
- Fiberglass
- 1/4" Plywood sheet
- Phenolic tube
Layup tools - West Systems epoxy (6 or 24-hour)
- 5-minute epoxy
- Popsicle sticks
- Fillet tool
- Squeegees
- Rollers
- Fin can jig and stabilizing feature
Bagging Materials - Release film
- Bleeder fabric
- Vacuum bag
- Peel ply
Miscellaneous - Spray glue
- Scissors
- Sandpaper (60, 120, 220 grit)
- Wax paper
- Dremel (with sanding bit)
- Sharpie
- Personal Protection Equipment
- Gloves
- Dust masks
- Safety glasses
- Respirators
Flight Fin Can Procedure
Required Materials
- Mylar (for initial layup over tube)
- Phenolic tube
- Carbon fiber (5.7 oz, 2x2 twill/plain weave)
- Wax paper
- Spray glue
- Epoxy (6 or 24 hour for root bond, not oven cure)
- Laminating epoxy (24 hour) if oven curing
- Boats for epoxy
- Squeegees
- Rollers
- 1/8" sheet of G10
- 1/4" sheet of phenolic
- Mandrel
- Proline
- Popsicle sticks (large and small)
- Fillet tool (3D printed?)
Bagging materials - Peel ply
- Bleeder fabric
- Release film
- Vacuum bag
- Vacuum tape
-15deg end mill (LOOK INTO THIS, talk to ethan)
Preparation:
FIT PHENOLIC OVER MOTOR TUBE
Fin jig
-1/4" MDF
-MAKE SURE HOLES ARE BIG ENOUGH
-Fin thickness
Test Fin Can Procedure
Cut and Sand Fins
1) Cut plywood fins to shape on the laser cutter
2) Put on safety glasses and a dust mask
3) Sand the face of each fin using 120 grit sandpaper
4) Bevel edges of fins using a Dremel and sanding bit
Cut and Sand Tube
) Cut phenolic tube to size
) Put on safety glasses and a dust mask
) Sand tube until it fits over the motor case (start with 60 grit, work up to 220)
) Score the tube (using 60-180 grit sandpaper)
Prepare Tip-to-Tip Cutouts
) Prepare paper cutouts for tip-to-tip layup
3) Stick wax to fiberglass using spray glue
4) Cut fiberglass shapes with scissors
5) Record mass of fiberglass (will use later to calculate wetness ratio)
6) Mark centerline of each piece with sharpie
Attach Fins to Tube (Root Bond)
) score fins
2) Put tube in fin can jig (MORE DETAIL)
) Put on gloves
) Mix epoxy
3) Put 5-minute on root chord of each fin
4) Slide fins into slots in the jig
5) Finish assembling jig (put top layer on --> push so that it gets caught on leading edge, BE CAREFUL after glue is set and of messing up LE
) Attach stabilizing feature
) Let cure
Root Fillet
) Remove the fin can from the jig
) Put on gloves and respirator, ensuring the respirator fits well with a positive/negative pressure test
) Mix laminating epoxy with colloidal silica
) Use fillet tool to add fillets
) let cure (24 hours)
) sand the root fillets
) mark centerlines on the tube
Tip-to-tip Layup
) Put on your respirator and gloves
) mix epoxy
) Record mass of epoxy used
) Wet the glass sheets with laminating epoxy using squeegees
) Layup the sheets
) Implement "Vacuum Procedure" (WHERE?)
Post -processing
Flight Fin Can Procedure
) cut fins
)wax spray CF
) cut shapes
) weight shapes
) cut tube to length
) make sure it fits over motor case
) score eryting
CF layup around tube
- + ONE DAY
) make appropriate fin jig
) assemble in fin jig , root bond
- WAIT one day
) prepare preforms
) do inner fillets
- + one day
) sand
) outer fillets
- + ONE DAY
) sand outer fillets
TIP TO TIP
) mix epoxy
)weigh epoxy
) layup
)bag it up til past tacking (+ ONE DAY)
) oven cure? (autoclave)
) sand
) eat donuts