Panel Materials

I am getting ready to replace the panel in my Ventus B. Are there any
standard materials (especially the core) and recommended glass and
core thickness used to layup a new one?

This is a fixed panel, does not pop up when the canopy is opened.

I was thinking of using a 1/16" to 1/8" core of DIVINYCELL. So far
the thinest I can find is 1/8", is this too thick and will it handle
the compression of mounting screws through it?

On Sep 27, 9:39 am, Tim Taylor wrote:
I am getting ready to replace the panel in my Ventus B. Are there any
standard materials (especially the core) and recommended glass and
core thickness used to layup a new one?

This is a fixed panel, does not pop up when the canopy is opened.

I was thinking of using a 1/16" to 1/8" core of DIVINYCELL. So far
the thinest I can find is 1/8", is this too thick and will it handle
the compression of mounting screws through it?

There is a company: Aerospace Composite Products, that has various
types of pre-make composite panels. All are carbon or glass with
various "fillers" of foam, glass, and something they call Corelite
Other panels of thicknesses over .5 inch are done with foam and balsa.

http://www.acp-composites.com/


I would check with them regarding using one of their panels to make
the blank.

I used many of their products in the past and they're always top of
the line.

Mike

On Sep 27, 4:36 pm, SoaringXCellence wrote:
On Sep 27, 9:39 am, Tim Taylor wrote:

I am getting ready to replace the panel in my Ventus B. Are there any
standard materials (especially the core) and recommended glass and
core thickness used to layup a new one?

This is a fixed panel, does not pop up when the canopy is opened.

I was thinking of using a 1/16" to 1/8" core of DIVINYCELL. So far
the thinest I can find is 1/8", is this too thick and will it handle
the compression of mounting screws through it?

There is a company: Aerospace Composite Products, that has various
types of pre-make composite panels. All are carbon or glass with
various "fillers" of foam, glass, and something they call Corelite
Other panels of thicknesses over .5 inch are done with foam and balsa.

http://www.acp-composites.com/

I would check with them regarding using one of their panels to make
the blank.

I used many of their products in the past and they're always top of
the line.

Mike

Make sure you have some kind of rounded flange around your legs,
lest the panel turn into a knife in an accident. You'll note all new
gliders have this feature. Make a mold with a thick piece of wood,
rounding the corners, and lay up a non-sandwich panel for best
results. Its easy and much safer than a simple panel (especially
a metal panel).

Hope this helps,
Best Regards, Dave "YO"

On Sep 27, 1:36 pm, SoaringXCellence wrote:
On Sep 27, 9:39 am, Tim Taylor wrote:

I am getting ready to replace the panel in my Ventus B. Are there any
standard materials (especially the core) and recommended glass and
core thickness used to layup a new one?

This is a fixed panel, does not pop up when the canopy is opened.

I was thinking of using a 1/16" to 1/8" core of DIVINYCELL. So far
the thinest I can find is 1/8", is this too thick and will it handle
the compression of mounting screws through it?

There is a company: Aerospace Composite Products, that has various
types of pre-make composite panels. All are carbon or glass with
various "fillers" of foam, glass, and something they call Corelite
Other panels of thicknesses over .5 inch are done with foam and balsa.

http://www.acp-composites.com/

I would check with them regarding using one of their panels to make
the blank.

I used many of their products in the past and they're always top of
the line.

Mike

The carbon fiber will be hard to cut and drill and will probably
require carbide tools. I would recommend fiberglass. Also if you
mold a fiberglass panel you can mold one with out the sharp edges.

Richard
www.craggyaero.com

"Richard" wrote in message
oups.com...
On Sep 27, 1:36 pm, SoaringXCellence wrote:
On Sep 27, 9:39 am, Tim Taylor wrote:

I am getting ready to replace the panel in my Ventus B. Are there any
standard materials (especially the core) and recommended glass and
core thickness used to layup a new one?

This is a fixed panel, does not pop up when the canopy is opened.

I was thinking of using a 1/16" to 1/8" core of DIVINYCELL. So far
the thinest I can find is 1/8", is this too thick and will it handle
the compression of mounting screws through it?

There is a company: Aerospace Composite Products, that has various
types of pre-make composite panels. All are carbon or glass with
various "fillers" of foam, glass, and something they call Corelite
Other panels of thicknesses over .5 inch are done with foam and balsa.

http://www.acp-composites.com/

I would check with them regarding using one of their panels to make
the blank.

I used many of their products in the past and they're always top of
the line.

Mike

The carbon fiber will be hard to cut and drill and will probably
require carbide tools. I would recommend fiberglass. Also if you
mold a fiberglass panel you can mold one with out the sharp edges.

Richard
www.craggyaero.com

I've drilled and cut carbon fiber/epoxy structures with ordinary wood and
metal tools. They work fine but do require more frequent sharpening. Do
wear a good respirator and eye protection when working with either
fiberglass or carbon.

Bill Daniels

If you are going to be doing any composite cutting, I'd make sure you
use a diamond bit or blade. Carbide works, but diamond will still last
longer. Also, if possible use water when cutting, this keeps the blade
cool and will make it last longer, and keep the dust down. Wet tile
saws work great.

Be sure to wear a mask, carbon fiber can get nasty.

Todd
www.sandwichpanels.org

On Sep 27, 10:39 am, Tim Taylor wrote:
I am getting ready to replace the panel in my Ventus B. Are there any
standard materials (especially the core) and recommended glass and
core thickness used to layup a new one?

This is a fixed panel, does not pop up when the canopy is opened.

I was thinking of using a 1/16" to 1/8" core of DIVINYCELL. So far
the thinest I can find is 1/8", is this too thick and will it handle
the compression of mounting screws through it?

For a panel I wouldn't bother with a core. I would just make it about
1/8 of Glass.
Depending on the Glass this usually only about 4 to 6 layers of glass
if I recall correctly. Maybe a few more if you vacuum bag it.

If you really need a thin core you might look at just using a peice of
aircraft plywood.

Brian Case
CFIIG/ASEL

Brian wrote:

If you really need a thin core you might look at just using a peice of
aircraft plywood.

You can also save a small amount of weight by using 1/8" medium to hard
model shop balsa for the core of a glassfibre panel - that's what
Libelle panels are made from. This may also make the panel easier to
make and to cut openings in than if it was ply. Glue the balsa together
with white wood glue before its final shaping and doing the glassfibre
layup.

If you put one or two layers of 200 gsm (6 oz/sq.yd) glass on either
side of the balsa you should have a good panel. Add a layer of 25 gsm
(3/4 oz/sq.yd) cloth outside the heavier cloth to get a nice, smooth
finish. As others have said, put a decently wide flange (25mm / 1")
round the bottom of the panel to protect your legs. If you make the
flange from all the layers surrounding the balsa that should do the trick.

As others have also said, if the panel is part of the fuselage structure
then buy a blank from the manufacturer.


--
martin@ | Martin Gregorie
gregorie. | Essex, UK
org |

On Sep 27, 10:39 am, Tim Taylor wrote:
I am getting ready to replace the panel in my Ventus B. Are there any
standard materials (especially the core) and recommended glass and
core thickness used to layup a new one?

This is a fixed panel, does not pop up when the canopy is opened.

I was thinking of using a 1/16" to 1/8" core of DIVINYCELL. So far
the thinest I can find is 1/8", is this too thick and will it handle
the compression of mounting screws through it?

For General purpose Epoxy fiberglass work I would recommend MGS
Epoxy. If you saw the floorpan in my HP16, that is what was made
with.

For the Glass I would just use Rutan Bidirectional Cloth. This is very
simlar to some of german cloth used in sailplanes (Also simlar to what
I used on my floorpan)

Both are available from Aircraft Spruce and are reasonably priced.

Brian Case
HP16T N16VP

Tim Taylor wrote:
I am getting ready to replace the panel in my Ventus B. Are there any
standard materials (especially the core) and recommended glass and
core thickness used to layup a new one?

Fixed panels are sometimes part of the cockpit structure or safety
design of the glider; e.g., to break instead of injuring the pilot's
legs. Check with the manufacturer before using a different material, or
if the glider is old enough, they might now recommend a different
material than the original material.

--
Eric Greenwell - Washington State, USA
* Change "netto" to "net" to email me directly
* "Transponders in Sailplanes" http://tinyurl.com/y739x4
* "A Guide to Self-launching Sailplane Operation" at www.motorglider.org