Openfuse: Hydrofoil main fuselage body.

This is a work in progress, aim is to have a fuselage compatible with many wings and masts. this is a start, with the front compatible with Gong hydrofoil front wings and gong/ F-one masts. The stabiliser is carried by a 12mm push in fibreglass rod. 

1. Glider open mould: The mould can be printed if your printer is big enough, I plan to CNC it, paint it with gel coat to seal it and cnc it again.

2. GliderBodyInt.stl is the insert that the composites need to be wound around. It includes voids for 12mm fibreglass rod to the stabiliser and for the mast. 3. GliderBodyExt.stl is a plug of the fuselage body shape without any of the voids. 4. GliderBodyCollar is a 3D printable part to smooth the transition from the stub end of the rear of the front wing's mast socket, this minimises disruption in fibre layup.

The idea is to wind all your composites around and through the mast hole of the internal part. Then push a 12mm fibreglass rod into the back end of it and close the mould around the composites and fibreglass rod after first polishing and applying release agent.

The internal part needs to be printed at high infill %, I recommend around 60% and cubic infil, max layer height of 0.175mm to ensure good overlap of the cubic infil.

Update 23/9/2020: Modified GliderbodyInt.stl to allow 2mm more inner thickness for fibre reinforcing layers. This is the extended 120mm insert version that matched the dimensions I've been given to fit a Gong wing socket for the aluminium fuselage.

GDWingXXLblock1200x3300x75.stl is a sample wing of my own design for cnc machine cutting.

Update 12 October: Corrected the direction and exttended the protrusion of the mast socket on both the inner former piece and channged from 60 sides to 360 sides for more smoothness. Redid the mould for  the corrections.

Update 3 November: First test of the new 1200mm wide wing last weekend prior to fine sand and polish. Very happy with the extra lift.  I did a .dxf variant of my 3D  fuselage design for CNC manufacture from 25mm thick aluminium slab and made one, it's the "2.5DGliderBx.dxf.stl" file, remove the .stl suffix and you can open it in a CNC CAM program (I'm using estlcam)

Settings:

Mast pocket: 6.2mm router, 21mm depth. (leaving 4mm base material)

Mast containment elipse: 6.2mm router, external part, 3mm depth.

End pockets:6.2mm router, 3mm depth

Perimeter part cut: 6.2mm router, 25mm depth, holding tabs 2mm high, install at corners, mast end just clear of wing plug and half way along fuselage. 

Holes: 6mm, 25.5 depth

I cleaned up with a band saw and used a rounding corner router bit with 3mm radius to clean up the wing plug length to make it Gong wing compatible.