Fillets

I've heard of making Fillets from micro ballons and epoxy, etc.

My question is, what is the best way to make good fillets, from what materials, name of products, how is the fillets formed, etc please?

I use both enamel and/or dope on my models, what is compatable with what please?

Another words from start to finish please, how does one make proper fillets please?

My sincere thanks.

Ken Wilson
Evansville, IN

>I've heard of making Fillets from micro ballons and epoxy,
>etc.
>
>My question is, what is the best way to make good fillets,
>from what materials, name of products, how is the fillets
>formed, etc please?
>
>I use both enamel and/or dope on my models, what is compatable
>with what please?
>
>Another words from start to finish please, how does one make
>proper fillets please?
>
>My sincere thanks.
>
>Ken Wilson
>Evansville, IN

Hi Ken;
I make all my fillets with epoxy and micro balloons. I use a type of epoxy called " 20 Minute Finish Cure Epoxy" that is made by Bob Smith Industries, and is carried by most hobby shops, and they put the hobby shop's name on the label. It is a thinner type of epoxy than yoru regular 5 minute or 30 minute epoxy. I mix a small amount , usually around a half ounce or less, depending on how much I think I need, and start adding the micro balloons. You will be surprised how much micro ballons you have to add to get it to the consistancy of cake icing or putty like. I then apply it to the model with a popsickle stick or something similar. Once I get it dragged all the way around, I wait for it to start to set up. When you add the micro balloons, it slows the working time way down. I dip the popsickle stick in alchohol and drag the fillets a little more to smooth them out, and even them up. Then I dp my finger in alchohol and do the same thing, and drag the edges down smoothe with the wing and the fuse side. Take you time with this part. You can smoothe and feather the edges down almost right up until the epoxy finally hardens, and the fillets will be baby butt smoothe. I usually never have to sand anything. Another advantage of this is that they do sand easy if you need to, and you get some added extra strength to the wing joint. I have never had these crack or come off, and all types of paint seem to stick to the surface very well, I've never had a paint job bubble or lift off of these fillets. Like anything else with model airplanes, it may take time and some practice to get what you want, but this method is the easiest I have used, and takes paint the best. When I first heard about this method,it was recommended to use HobbyPoxy Smoothe and Easy epoxy, but this brand isn't available anymore, but I think the Bob Smith brands are available to most people, and their epoxy and C/A glues are pretty good quality and consistancy. IO would think that any type of finish cure or lay up type of epoxy will work, and maybe even regular 30 minute epoxy will work, but I haven't tried it yet.
Good luck and have fun,
Dan McEntee

Many thanks Dan for going into the details of making good fillets.

Most Sincerely,

Ken Wilson
Evansville, IN

I still think SuperFil (made by Poly-Fiber) is superior to anything else out there. It's easier to sand that epoxy and micro-balloons or 404 filler, seems to be easier to handle and shape than either these or Aeropoxy and is most certainly lighter than any of them.

And I've had zero adhesion problems with paint since I started using it.

Shouldhave read the entire post before responding. Dan is right about process, though I recently started using a trick little tools for shaping the initial fillets. It's a sort of steel ball affixed to the end of a rod. Dipped in alcohol and run down the fillet, it leaves a very nice surface. Sandins after it cures is much easier.

>I still think SuperFil is superior to anything else out
>there. It's easier to sand that epoxy and micro-balloons or
>404 filler, seems to be easier to handle and shape than either
>these or Aeropoxy and is most certainly lighter than any of
>them.
>
>And I've had zero adhesion problems with paint since I started
>using it.


Randy;
Been having good success with the finish cure epoxy/micro balloon system, so I haven't looked at or tried anything else.
What is SuperFill and where do youfind it? I like to keep an open mind to new stuff.
Thanks in advance,
Dan McEntee

Dan,

SuperFil is a full sized airplane fillet maker. I get it from Aircraft Spruce but you can also get it from Poly-Fiber, the maker.

http://www.aircraftspruce.com/catalog/cmpages/superfil.php

http://www.stitspolyfiber.com/superfil.html

Bob Smiley first turned me onto this stuff. He used it when building his Lancair. It's very cool stuff. Nothing at all wrong with using epoxy and micro-balloons. But I just like this stuff better.

>Dan,
>
>SuperFil is a full sized airplane fillet maker. I get it from
>Aircraft Spruce but you can also get it from Poly-Fiber, the
>maker.
>
>http://www.aircraftspruce.com/catalog/cmpages/superfil.php
>
>http://www.stitspolyfiber.com/superfil.html
>
>Bob Smiley first turned me onto this stuff. He used it when
>building his Lancair. It's very cool stuff. Nothing at all
>wrong with using epoxy and micro-balloons. But I just like
>this stuff better.

I would venture to say we're talking about similar methods. I think it wouldn't be too much of a guess that the SuperFil is basically the same thing, with the Micro balloons or fiber filler material is already mixed into one half of the glue. Same benefits from both methods. the surface may feel smooth to the touch, but is really pretty pourous and that lets the paint lock on to it.
I would like to try this stuff, but with the rate that I get to build airplanes,(about one in the last ten years ) it owuldn't be very cost effective!
Dan McEntee

Hi Randy:

The tool you refer to is the the pattern makers' tooling ball. Used for puting wax fillets into patterns prior to molding sand or whatever.

They heat them in hot water and push them onto the coiled wax material--much like the leather fillet stock that is sold.

Works good on epoxy also.

I spread and rough tool with a prop blade-like tool then smooth with a foam swab in alcohol. The swab is elliptical in shape and pulls a real smooth finish. Just need to break the surface slightly prior to painting.

I think the real trick is to put them on so they don't need any work with sanding to get them clean and smooth.

I used to practice where the road meets the driveway.

Curt

Capt,

Yea, I got them from Micro-Mark, but never paid much attention to what they were actually supposed to be used for. Sure work nicely for making fillets.

OK, I went and looked. What I have is a set of reducing punches.

http://www.ares-server.com/Ares/Ares.asp?MerchantID=RET01229&Action=Catalog&Type=Product&ID=82390

Work pretty well

I go along with Randy 10000000%

When I was building JD Falcon kit prototype, I used a much recommended product from a major supplier. The fillets popped. I re-did them and they popped again. I was ready to step on the airplane I was so frustrated.

Talking to a friend in Ohio he mentioned that Billy was using the Superfil.

I completed carved out the fillets and used the Superfil.. and have been using them on everything since with no problems. I would hate to count up the hours lost using the other stuff.

The Superfil comes in 1qt size 2to1 mix. under $20. This is good for quite a few airplanes. It seems to have relatively long shelf life.It is the only product that I will use now.

Dont forget leather fillets.If you google you will find a supplier that sells them in 100 ft. bundles ,but there is a guy who supplies them in small quantities advertising occasionally in Stunt News. One guy in our club uses them and thet certainly look good . Are preshaped to whatever radius you order and are glued on using Ambroid. Very light and porous enough for paint adhesion. Anybody know the name of the supplier?? Keith Varley

Bill Sawyer of Windancer Models..

Leather Fillets

I'm with Tom. You'll never get me to use anything else. Very cool stuff.

Yes...

They look like the same thing.

Curt

I have used Super fill and will NEVER Change because it's like Skippy creamy style, Long working time, and sands great, and light weight. If anyone uses this I would like to know if they go back to their other product, and why? The best part of the fill job on the Roadrunner I did is the push rod exit cover where it meets with the center sheeting. hard to see in this photo.

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