Learjet 45 Simulator Project » Shell

Where Does the Time Go?

Captain — Sun, 11 Dec 2011 01:43:25 +0000

Well, My mini shell finally arrived. I had to thicken the inside for added strength. Here you can see I’ve got it masked and am adding layers of paint for final shaping. This has become quite the mini project in itself. At least this feels like I’m still building.

It’s gonna look great on top of my mini motion platform.

Mini Learjet 45 Shell for Mini Motion Platform

Waiting…

Captain — Fri, 04 Nov 2011 21:53:36 +0000

Shapeways is backed up with orders. I had expected to have my mini Learjet shell by now. I won’t have any pictures until it arrives and I can complete the test platform.

3D Modeling (Booleans are Bad Mmmkay)

Captain — Mon, 01 Aug 2011 03:24:17 +0000

I’m working on a 3D model of the Learjet 45 that I will eventually be 3D printing for my miniature motion base test setup. My last serious run at modeling was back n the mid ’90s, so I’m kind of rusty. I apparently forgot that Boolean Operations can wreak havoc on meshes, so my idea of cutting the windows out of this thing with Booleans, is a wash. I’ll need to take a few steps back to see if there’s another way without starting over. Good thing I saved all those iterative versions.

Learjet 45 3D Model

Hey! Who put a Learjet in my Basement?

Captain — Tue, 16 Nov 2010 03:31:04 +0000

The foam has hardened, and just one more coat of paint up top before the real fun begins.

Learjet 45 Simulator Cockpit Shell

Painting the Shell

Captain — Sun, 24 Oct 2010 03:36:11 +0000

The port and starboard side foam has been hardened and I’ve applied a fresh coat of paint. It’s a slightly different color than the Apple Green I’ve been using, but the final coat will be Apple Green. If you were wondering why I’m using green, it’s very close to the special corrosion-resistant paint used on the frame parts of real airplanes.

My experiment with fiberglass is continuing. Apparently it can take up to two weeks for the Paverpol to harden completely. Right now the test piece is still a little flexible. Either the Paverpol isn’t completely cured yet, or I need to add a few more layers of fiberglass. We’ll see.

Learjet 45 Flight Simulator Cockpit Shell Painting Progress

Shell – Star Wars Edition

Captain — Sat, 10 Jul 2010 22:43:20 +0000

The shaping is nearly complete. I’m finally cutting around the edges so the panels will come loose again. The pattern on the panels gives the shell a different look. It reminds me of something that happened a long time ago in a galaxy far far away…

Learjet 45 Simulator Shell

… and He Disappeared in a Cloud of Dust.

Captain — Sun, 09 May 2010 01:10:52 +0000

I’m making great progress with the final shaping. Unfortunately, the foam putty I’m using is hard to get locally and in limited supply online too. I have to order it and wait for the next batch to arrive in order to progress further. I’m also being my usual perfectionist self, so that doesn’t help either.

It’s looking good though and there are only a few rough spots I need to clean up on the sides and the top, so sealing and painting will happen soon. I wasn’t as careful with applying the putty, and it got in the spaces that it shouldn’t have, so I’ll need to carve around the edges to get the panels to pop out like they’re supposed to. I’m not worried about that at all. It’s just one more thing on my list.

Learjet 45 Simulator Shell Side View Close-up

Learjet 45 Simulator Shell Front View

Shell Update

Captain — Sun, 18 Apr 2010 21:18:35 +0000

Um, yea. This sanding bit is taking much longer than I expected. Big surprise huh?

Port Side Foam Putty Skim Coat

Captain — Sat, 13 Mar 2010 03:44:08 +0000

If I do this right, I shouldn’t have too much touch-up work after this sanding pass.

Learjet 45 Simulator Cockpit Shell Port Side Foam Putty Skim Coat

Final Shaping Started

Captain — Mon, 08 Mar 2010 00:01:18 +0000

Well, the port side final shaping is under way. I’m using adjustable flexible sanders from AFS that are typically used on cars, but they work great on any curved surface.

Learjet 45 Simulator Cockpit Shell Final Shaping

Learjet 45 Simulator Cockpit Shell Shaping Close-up

AFS Adjustable Flexible Sanders