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Old 05-13-2010, 09:26 PM
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Monnett Sonex

I've been looking around for a fairly simple model as a learning vehicle for a natural aluminum finish model. After more than a few false starts I decided that a simple home built aircraft would be the best way forward. I settled on John Monnett's Sonex. Strange enough I couldn't find anything better than a crude three view on the vendor's site. What convinced me to move forward on the project was the rich builder blog resource on the web. Importing part photographs into Rhino using the PictureFrame command allows dimensioning through quick line traces followed by scaling the proportional part into the drawing (it's all about perspective here). It's much easier than I thought it would be but it did take some time to refine the method.

The following drawing required only two evenings of work to obtain the level shown below.

+Gil


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Old 05-14-2010, 06:19 AM
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Awesome. That's one plane I've thought would be fun to build. They flew one on electric power at Oshkosh two years ago!

Ryan
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Old 05-14-2010, 07:26 AM
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Hey nice choice of aircraft Gil!

The fact that you did that in 2 evenings.........well it would take me alot longer. I might have to look at Rhino here in the near future!

Bravo good sir, bravo!
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Old 05-15-2010, 11:54 AM
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Support Tech: Gluing Aluminum

The following photograph shows two test pieces of aluminum tooling foil bonded together using urethane glue (that's been modified slightly for the application).
This is a required solution that enables use of aluminum in modeling. The rivet detail was applied with a pounce wheel for show...

+Gil


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Old 05-16-2010, 09:23 PM
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So you're going to build the model out of aluminum like the real thing?
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Old 05-17-2010, 01:16 AM
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...out of aluminum like the real thing?

Yes, like the real thing...

+Gil
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Old 05-17-2010, 09:17 PM
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You sir are my hero.

Where might one obtain this aluminum tooling foil you speak of? It's not standard aluminum foil is it?
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Old 05-18-2010, 12:30 AM
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Tooling Foil

Most of all the online sources are supplied by St. Louis Crafts, Inc.:

New Page 1

Their resellers are:

www.dickblick.com
www.schoolspecialty.com
www.unitednow.com
www.kurtzbros.com
www.eNASCO.com
www.pearlpaint.com
www.sbarsonline.com
www.gregdorrance.com

+Gil
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Old 05-18-2010, 07:04 AM
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I just use large size beer and soda cans. I cut them into flat sheets and use paint remover to get the back to bare aluminum. From all my experiments, only Urethane glues will bind the aluminum pieces together.
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Old 05-18-2010, 09:44 AM
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Discovery Process...

I tried aluminum cans also. Finally realized that the hassle of removing labeling (paint remover) and getting the surface flat was too much trouble considering that the aluminum alloy used will not temper to "soft" or "dead soft". It's good for some applications but can't easily be "worked" for many modeling applications. Conversely, tooling foil is dead soft and can be formed into about any shape necessary to produce a modeling aluminum analog.

I came to the same conclusion regarding the use of urethane glue. Thinning it a little with toluene makes it easier to apply...


+Gil
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