[Raptorfly]

After trying to cover the fuse in many different ways and different things... I gave up..
It's simply impossible to get that beautiful curved body by just covering it...
So instead of sanding down full square block glued together, then Carving the inside to lighten the weight.. I decided to make the fuse out of fillets... yes, I'm cutting over 100+ 12mm slices a few millimeters over size and will glue them together in sections and sand them down to shape...I hope this works..

Foamcoat just arrived.. so I will be testing that too.
                   

[Raptorfly]

I cut some more fillets and I'm almost done... 18 to go tonight.

I also tested the Foamcoat on a piece of xps foam. Its a little on the thick/paste texture than smooth flowing paint... so it brushes on uneven and with various thickness. I did a few tests with thick coat and thin coat and I think a few thin coats would be the better way to go. They say for a smooth finish wipe with wet sponge just before it starts to set... will try that too. I sanded a dried up sample and it seems to come up nice and smooth and hard enough to protect the foam.

[Raptorfly]

Slices all glued together.. now need some serious and accurate sandinig.. will cut profile templets out of cardboard to sand the shape to...Some progress pics..

               

[smuzz]

Impressive, George

[Flying fisho]

Mucdoneh more patience & skill than I could ever hope to achieve. Well

[Raptorfly]

Didn't fly last weekend as I was flying to WA for work.. So I did more work on the superconnie...
Sanding, Sanding, foamcoat, Sanding and sanding the foamcoat almost completely off... I need to get this fuse as smooth and curvy as possible... so I will continue sanding and coating.. then sanding some more......

Pics
                                               

[secant0give]

Looking good george !!
I'll be interested to see how the foam coat goes and what it's like in the flesh so to speak

[wingtipper]

yeah mate . watching keenly .

[Raptorfly]

Wet and Windy Sunday... more sanding and then glassed it with 18g cloth and water based varnish, needed to give it strength and bond the slices together. Foamcoat is very thick... I thinned it down with the varnish (next time I'll try just water).. applied it on top of the cloth.. hmmm very thick like mixed filler powder.
I don't think I like this foamcoat stuff... it doesn't settle and smooth out like paint. It seems heavy and leaves all the grooves and brush strokes which needs to be sanded down... And I sanded and sanded and still cannot get the surface to smooth out. I will sand most of it off and hope to get a smooth surface and reduce the weight.
Some pics.

[gbanger]

Looks like you are getting there George.....
I think you have the paitience of a saint!!!!
Gazz

[Raptorfly]

Ok, back on Sanding the foam coat almost completely off the fuse... Just doesn’t set smooth and I think it adds too much weight.
So after sanding and sanding and dust all over me and the garage... I'm sure my lungs are not happy either..
Time to start hacking into it, to test mount the wings and making it ready for the electrics and retracts...
the wings still need to be wired up, and motor mounts fitted before I can glue the top and bottom halves then shape the leading and trailing edges before I cut the ailerons and flaps out.

Some pics
                                           

[Flying fisho]

Looking good George, you have more patience than me

[secant0give]

That's comming allong NICE George, You've certainly captured the essence of the Conny !!
It's good to see some serious building taking place !!

[wingtipper]

cant wait to see this one in the air mate .