The Corsair82: 82% F4U-1A Corsair

Before I put the fuselage back in the molds I wanted to make the canopy frame mold. I can then scribe all of the points needed onto the fuselage molds for future use.

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I had to make a canopy slide track. This was not so easy. Finding the right materials was a task. I had to make a lot of it.
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The roller on the front left corner of my fiberglass canopy mock up.
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Both side now have rollers. It worked reasonably well, but needs more work.
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I needed to make a template of the front and rear of the canopy.
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Both templates on a centerline.
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A paper transfer of the template on my table.
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A steel channel is bent to form the canopy frame.
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I had to heat it a little.
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The bow in place.
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The canopy front and rear bows are connected and the windscreen bow in place.
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Aluminum is riveted in place.
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A windscreen mock up is in place to give me the angle at of the top of the bow. This is an important angle. It must also be transferred into the canopy bubble.
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The top aluminum is in place but needs a lot of work.
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The finished canopy frame.
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The only thing is, I don??t like working with aluminum!
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I decided to do it over in fiberglass. That means making a plug.
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The plug needs a frame and a windscreen.
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It needs strong support so it doesn??t move while the mold is being built.
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The aluminum will serve as a plug surface. I scribed the shape of the canopy frame into the aluminum. This will transfer to the mold and then to the parts made in the mold.
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The mold is done.
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The mold needs a frame to hold its shape.
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The mold has been removed and trimmed. The surface is very nice because of the finish on the aluminum.
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Checking the fit.
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Making the new composite canopy frame using vacuum infusion.
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The new frame.
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Nice fit.
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Now the frame has been trimmed.
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Time to make a mold for the windscreen frame. That means another plug must be built.
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Checking for symmetry.


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