How to build an all Carbon composite airframe on an aluminum mandrel.

This is the equipment:

• A roller stand. This one will accommodate mandrel sizes from 2 inch OD to 6 inch OD or more. I used 1.5 inch diameter cam followers but hardware store wheels will suffice.
• An aluminum mandrel (in this case 3.0 in. dia. x 60 in. long x .125 in. wall). Available from http://www.onlinemetals.com/ in various sizes.
• An electric paint stripper.
• A thermometer.
• A piccolo heater manifold. The piccolo manifold is 1.00 in. dia. copper tubing, cross drilled with .187 in. dia. holes. The pitch distance of the holes tapers from 6.0 inches at the inlet end to 3.25 inches at the plugged end. The purpose of the tapered hole distribution is to prevent the end closest to the heater from being hotter than the far end. This pattern worked well for me; there was only a few degrees difference from one end of the mandrel to the other end.

The mandrel rotates freely around the stationary heater manifold.

The mandrel is prepared by paste waxing and covered with a mold release compound. Wicks Aircraft Supply http://www.wicksaircraft.com/ and many other places have these supplies.

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