OK. After moving from Kiama, NSW to Bonner, ACT we restarted the build. The new garage is now decluttered and the workbench visible.
Each wing is 1.6m long and was delivered in halves. We have now joined the foam molds and the wing halves with epoxy.
We have also completed the CF wing spars. 2mm rod into 4mm tube (2mm inside diameter) into 6mm tube (4mm inside diameter) giving 2 x 1.6m tapered spars.
Next step is to coat the foam cores with a 2-part water-based polyurethane. I received some free samples from Hychem in Sydney. This is the same stuff used to coat garage and shopping centre floors. Very tough. We'll sand most of it off again to give a strong skin to the flimsy foam before installing spars and covering with Koverall and more WBPU.
Question: I am planning to install aileron servos, spoiler servos, electric retracts and LED navigation lights (rc-lights.com). Should I install a majority of the required power/control wiring in the channel with the wing spars? Pics soon.
Each wing is 1.6m long and was delivered in halves. We have now joined the foam molds and the wing halves with epoxy.
We have also completed the CF wing spars. 2mm rod into 4mm tube (2mm inside diameter) into 6mm tube (4mm inside diameter) giving 2 x 1.6m tapered spars.
Next step is to coat the foam cores with a 2-part water-based polyurethane. I received some free samples from Hychem in Sydney. This is the same stuff used to coat garage and shopping centre floors. Very tough. We'll sand most of it off again to give a strong skin to the flimsy foam before installing spars and covering with Koverall and more WBPU.
Question: I am planning to install aileron servos, spoiler servos, electric retracts and LED navigation lights (rc-lights.com). Should I install a majority of the required power/control wiring in the channel with the wing spars? Pics soon.
Some specs for the build (mm):
Wingspan - 3325
Root Chord - 195
Tip Chord - 69
Mean Aerodynamic Chord (MAC) - 142
Wing Aspect Ratio - 25
Wing Area - 0.42 sq m
Wing Dihedral - 2deg
Wing Sweep - 5deg @ 1/4 chord
Fuselage length - 1210
Fuselage Width - 120 to 150
Fuselage max height - 250
EDF diameter - 90
V-Tail angle = 84deg
Wheelbase - 560
Some pics so far:
Wing halves and their form blocks joined
Forms blocks opened showing wing cores in situ 
The wing cores
Wing airfoil - NASA LRN 1015
CF reinforcing ready for installation. 6mm tube to 4mm tube to 2mm rod
CF Reinforcing rod (yet to be installed)
V-tail cores
V-tail airfoil - NACA0008
Comments
looks Good!
The NASA LNR 1015 airfoil is the airfoil used by the real Global Hawk. I checked out it's characteristics at http://www.worldofkrauss.com/foils/874 and liked what I saw.
The polyurethane product is a 2-part epoxy water-based polyurethane which was developed for sealing concrete floors safely. It is basically a tougher version of the WBPU products like Cabot's for timber floors. I will be using it as a substitute for fibreglass epoxy. I will still use cloth (Koverall for the wings and probably kevlar or fibreglass cloth for the fuselage. Being water based it is low fume and easy to clean up.
Which polyurethane product are you using? Does it provide any structural strength or just impact resistance?
May I ask, what factors are behind selecting the airfoil NASA LRN 1015? Nice work, please keep us updated on your progress and findings.
Impressive, I'm not sure if I missed it, but what kind of foam are you using?
how many r u going to make?