Gear Doors

How do you make a couple of gear doors? If you have a mould, it's no problem, using some glass clothing, epoxy and gelcoat. But how do you produce a mould? Have a look at some pictures if you could do with a bit of inspiration.

• Make a saw for expanded polystyrene using a broom handle, pieces of wood , thin iron wire, and a spring.
• The saw shall have a radius corresponding to the fuselage.
• Place a roll of line on the broom handle with a hammer tied on the string to give a constant torque.
• Use two 12 v battery chargers connected in series on the 220 V side, each getting 110 V. Connect the 12 V outputs in parallel.
• Shape two pieces of candle as bearings for the broom handle. Fix the candle pieces so they are not moved by the torque force.
• Make a cylindrical cut in a piece of expanded polystyrene.
• Glue 1 mm plywood on the mould, using polyurethane glue. Place the cut out piece on top and apply pressure using lots of books or the like.
• Use filler and sand the mould to a nice surface.
• Cover the plywood with a clear adhesive plastic (called Filmolux in Denmark) the type you use for protecting books. Ask your bookstore.
• Apply an even layer of gelcoat on top of the plastic and let it harden.
• Cut out pieces of the expanded polystyrene to form enforcements.
• Build the gear doors in the mould.