'R0' dome build - 3.4 'Skin - recessed box no.3'

Did some smooth sanding on the dome skin etc. Now silky smooth, ready for painting.

But first I still need to work on the last rear recessed box.

So I cut out the recessed pieces and started to glue them in place.

This time I cut the recessed pieces as two parts, not four. This was a LOT easier to glue in place.

There's a packing piece of wood to spread the load of the clamps, and this also helped the skin to shape more curved at the opening. I didn't take a pic of the other side, but it looks the same lol.

** Celebration Europe 2016 - New Polo shirt**

With only weeks left before Celebration Europe, I needed to get on the next run of logo'ed up tops from the UK R2 Builders Club.

Big thanks to Giles (Artoojayzero) for sorting these quality items.

Got my name on it like before, so I know who I am ;D

Also picked up these very classy 'gold' UK Builders Club patches.

So if your coming to the event, don't forget to come say hi :)

'R0' dome build - 3.3 'Dome filler'

I wasn't happy with how this edge of the dome skin curved inwards to much. This is where the extra inner support could of been better placed to help the skin's curvature, as the wood just wants to sit flat. So I decided to pack it out with wood & filler. Firstly I used a straight edge to gauge how far out it needed to be extended. Then I glued three scrap pieces of wood in place to fill in the depth.

In the above pic, you can see where I've pencilled in an a max area, as a guide. I then mixed up a small amount and started to apply it to the area.

Once dried I applied more filler, sanded and shaped.

In the second pic you can see that the lower edge is more curved. Feathering the edges of the filler to blend it all in.

Oh and I also glued two more squares in place.

R0' dome build - 3.2 'Dome PVA sealed'

I didn't get the chance to do this before going away the other week, but did, once I had five min's free on my return.
I mixed up normal PVA wood glue in with water and 'painted' it on to the Dome.

 Radar Eye, re-fitted, so I know what work needs doing i.e. gaps to be filled.

Once it's dried I can then sand edges and get it all ready for primer spraying. Still a few more panels left to make. But almost there.....

'R0' dome build - 3.1 'Dome lid'

Started work on the lid angle.

I should of made the lower of the two height discs, a larger diameter. So as to take up space, therefore, using less glass fibre resin. Packed out with scrap wood to a diameter of 140mm. Glued in place, then started with the glass fibre.

Building up in stages as then I can finish off with filler.

It was late, so this was as far as I got.

Wasn't able to do much more over the weekend.

'R0' dome build - 3.0 'Dome Lid'

Last nights work:

Cut out last piece of the lid sections.

Marked their positions on the main base ring (to be), then drilled holes and secured then to it.

The height of the lid is given as 9mm, so I measured and marked two 100mm discs, both 3mm thick (+ the base) equals 9mm high. I found the centre on the base disc and positioned where the discs would go.

Disc's marked out and cut out 

Positioned centrally

Next I glued the two discs together. These will be glued to the base disc, before the lid angles are created.


I then marked out the excess material not needed, to keep weight down, and used my jigsaw, cut sections out.

marked out area to be removed

And afterwards. The central hole will be used for a sleeve unit for the pop up system.
[If I have time before Celebration Europe, that is]

'R0' dome build - 2.9 'Dome Lid'

Next was the dome lid. I found the top ring cut out and marked where the centre was going to be cut out. This will help keep the weight down.

Then using what sheet material I had, I marked out the 'recessed' Lip ring (which will be silver) & the lower edge of the actual lid.These are half sections as didn't have enough for whole discs.

I've an idea how to secure the lid, but first, I'll finish this bit.

~~~

Lol, was moving bags hanging up in garage, when I found the leftovers of another project from years ago, Aluminium grill! Perfect!

It's not circular holes, like I've seen, but this is an R5 knock-off lol, so will do for this build.
My plan is to secure it to the inside of the pictured ring it's sat on. Cut down in height tho.

'R0' dome build - 2.8 'Squares'

Before and after of this panel fitting, still work in progress

Glued in place last two rear panel pieces. And then worked on the square panels, gluing in place and applying wood filler.

Almost finished these now, just four more to go....

'R0' dome build - 2.7 'Skin & squares'

Weekend work:

Limited free time on Friday night, but managed to get some work done.

Cut out one more 'square', and then glued in one of the two rear panels I made earlier. Then whilst that was drying, I did some filling with filler in spots, removed some more retaining screws and pins and filled these too. Did some sanding and shaping of one lower edge that had the gap. This requires building up the edge to get the shape.

lower skin edge work

Also worked on the 'square' inside face that won't need a panel* made for it. (above pic)

Applied some more filler to blend in the inside faces of the recessed boxes.

* NOTE:
After cutting out the squares......they didn't ACTUALLY need cutting out, as seen in a ref pic I found. Then when re-reading Sigge's instructions, yep, I had mis-read his instructions. I could of just grooved them out. Lol, never mind, I still have some of the cut out pieces I can reuse and the grooves around these panels gives them more depth and a 'real' thickness to the dome.

The sample piece of frosted plastic arrived Saturday morning so measured it up and cut it to size. At first I was thinking of flush fitting it to the dome as it's thickness is to much to curve to the dome, but I want it to be curved, so onto the next frosted plastic.....

Did some more rear panel work, cutting out and grooving the rear. This is very time consuming process.

Test fitting of square on dome.

And then gluing them in position.

Then I had the issue of the second square cut out that was partially covered by a vertical support.
I cut out the panel as best I could, then scrapped away the remaining wood that was bonded to the vertical.

Next I cut a piece of backing that would fit and glued it into place.

This piece will need extra filler around where the groove will be.

'R0' dome build - 2.6 'Skin & squares'

Didn't have much free time last night, but wanted to try and glue one of the panels in place. With limited tools I couldn't clamp it in place to easily, so had to use a scrap piece of wood long enough to reach inside, the length of the dome and use my clamp to apply pressure to keep the panel in place whilst the PVA glue set.

It worked! These will have fibre glass resin applied around the edges etc for added strength from 'prodding' fingers lol.

This morning I've cut out two more rear panels & managed to get one grooved. Will get the other grooved lunchtime and can then glue both into place tonight.

........more updates on Monday.....