aluminum mold for DLG control horns

up
test fitting Mark Drela's diagram to the pieces of aluminum I had handy

I used smaller alignment pins than specified because my mold is much smaller, but still felt that it would make it much easier to use with pins.  Open to suggestions for other designs.

the aluminum is just scrap I found



switchjack installed on my Sean Porter pod

switchjack.  Balsa wood shaped to curve of the pod and glued in with thick CA and accelerator

I'm sure there's some aero penalty to the hole, but it's probably not that bad

one of the outside pieces on the mold

the ugly outside piece

the working side of the mold.  The ugly hole (of the four small ones) was a broken drill bit because I didn't back-drill far enough



working sides; the countersunk dimples are probably a little deeper than the plans call for but they provide a bushing area for the pushrod

illustration showing how the 3K CF tow is wrapped around the pins to provide extra strength



ugly pockets were hogged out with a dull mill to pick out broken drill bits.  Bit broke from a combination of bad technique (backdrilled hole wasn't deep enough) and a crappy box of Chinese bits that snap very easily, even when good technique is used.

non-working side



terrible exposure

terrible exposure

terrible exposure


All images copyright Peter Jensen.