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  1. sandbagger's Avatar
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    Aug 13, 2017, 2:32 AM - Builds By Baz- Full scale Mk II Colonial Viper #1

    I first had this idea years ago, along with a couple of other projects I may move onto after it. With all the iron man stuff, photography, astronomy and knife making going on, it didn't look like I was ever going to do it.

    A few years ago, tried a paper model from online and just blowing that up and started a life-size cardboard version, but didn't like the shape of it. After sitting in my shed for nearly a year taking up space, I destroyed it.





    Next I grabbed a Mobeius kit and took Vernier caliper measurements from the physical model and multiplied them by the scale factor of about three. I made a concept model three times the size in cardboard and wood, threw some lights in it and worked out how the modular sections will assemble on site for transport and pull-down.

















    I only built one side of it so the other side can stay open for future visual planning. I mirrored a couple of photos for fun. (above)

    I've been collecting plywood and foam, among other materials for many months. For the last couple of years I've been trying to get shop drawings out of any CAD specialist willing to help, but I understand it's a lot of work for free and it's a big ask to dedicate the time.

    Even using verniers and blowing it up three times, brought inaccuracies I can't accept, so I really needed to get dimensions accurate.

    Now that I have a CAD expert helping me, I finally have accurate shop drawings and have started on the first two and a bit metres of the nose.

    The craft will use a variety of materials to make it, depending on strength/safety and where it is needed. The majority will be plywood frame, some aluminium longerons etc for strength, polystyrene foam fill for sculpting, then skinned with fibreglass.

    The cockpit and undercarriage will be constructed in such a way that it is safe to support and adult's weight and then some.

    The entire ship tops out at 8.4 metres in length.

    I have big plans for the rest of the ship, but I will tell the story as I go, rather than skip to the last chapter.





    Since my first thoughts of this years ago, I was dismayed to go online searching for blueprints, not finding any, but finding at least two other full scale Vipers out there. One is in full aluminium and a little further along than mine, the other is a plywood, completed and recently unveiled in Manchester. I think they are both 1978 versions, where as mine is the reimagined 2003 version.

    Just goes to show what can happen if you don't act on your dreams right away. Someone else will!
    Last edited by sandbagger; Aug 13, 2017 at 2:56 AM.
  2. C17ldmstr's Avatar
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    Aug 13, 2017, 12:25 PM - Re: Builds By Baz- Full scale Mk II Colonial Viper #2

    IronMan AND a Viper!!?? Amazing.
  3. SofaKing01's Avatar
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    Aug 14, 2017, 2:46 PM - Re: Builds By Baz- Full scale Mk II Colonial Viper #3

    I am so looking forward to seeing this!
  4. sandbagger's Avatar
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    Aug 15, 2017, 10:30 AM - Re: Builds By Baz- Full scale Mk II Colonial Viper #4

    Trying to be sooooo super quiet with the impact driver. It's getting late. Perhaps tomorrow I might get a chance...


  5. sandbagger's Avatar
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    Aug 16, 2017, 7:15 AM - Re: Builds By Baz- Full scale Mk II Colonial Viper #5

    Grinding the ends off the stringer screws.





    Next stringers plotted out for cutting tomorrow. I have a full day on it tomorrow, so should get a fair bit done. Might even get started on polystyrene bodywork if I'm not interrupted. Not holding my breath though.


  6. Formerly KCGhostbuster RPF Premium Member Snow Builder's Avatar
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    Aug 16, 2017, 9:10 AM - Re: Builds By Baz- Full scale Mk II Colonial Viper #6

    Subbed! Can't wait to for your next post.
  7. sandbagger's Avatar
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    Aug 17, 2017, 5:58 AM - Re: Builds By Baz- Full scale Mk II Colonial Viper #7

    I got quite a lot done today. Finished all the horizontal and vertical stingers in the nose. Then some strategic weight reduction was in order. I broke my 30 year old hole saw set, so it was off to Bunnings for a new and better set.


    Once I plotted out all the vertical stringers I removed them and cut the centres out of all the formers.


    Tomorrow I will attach them permanently and fix some aluminium longerons along the top and sides to lock it all in. Mission accomplished, the frame is now set to be rigid and light.


    To see WIP photos click here





    Last edited by sandbagger; Aug 17, 2017 at 6:04 AM.
  8. George's Avatar
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    Aug 17, 2017, 6:12 PM - Re: Builds By Baz- Full scale Mk II Colonial Viper #8

    Another amazing journey you're about to embark on.
    Thank you for sharing this,SB!
  9. sandbagger's Avatar
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    Aug 18, 2017, 2:25 AM - Re: Builds By Baz- Full scale Mk II Colonial Viper #9

    George said: View Post
    Another amazing journey you're about to embark on.
    Thank you for sharing this,SB!
    As always, my pleasure George! I hope I'm up to the task!

    SB
  10. RPF Premium Member Stormy320's Avatar
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    Aug 18, 2017, 2:50 AM - Re: Builds By Baz- Full scale Mk II Colonial Viper #10

    No he didn't say lifesize. Wait - I think he did
  11. sandbagger's Avatar
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    Aug 18, 2017, 4:18 AM - Re: Builds By Baz- Full scale Mk II Colonial Viper #11

    Help? Trying to find some reference as to scale, (dimensions) of this panel so I can start making it.





  12. sandbagger's Avatar
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    Aug 18, 2017, 4:36 AM - Re: Builds By Baz- Full scale Mk II Colonial Viper #12

    http://www.broadcaststore.com/pdf/model/7123/7123.pdf

    I found this pdf on the consol specs for the entire unit. Looks like it's anywhere between 19 to 22 inches across. If I can establish the actual length of the control panel, I have a scale to work from.
  13. eethan's Avatar
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    Aug 18, 2017, 12:20 PM - Re: Builds By Baz- Full scale Mk II Colonial Viper #13

    oh, great! I'll be following that project!
  14. RPF Premium Member
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    Aug 18, 2017, 6:18 PM - Re: Builds By Baz- Full scale Mk II Colonial Viper #14

    Awesome let me take her out for a spin when shes done and I will tell you how she flys!
  15. sandbagger's Avatar
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    Aug 19, 2017, 5:17 AM - Re: Builds By Baz- Full scale Mk II Colonial Viper #15

    I got about three hours of frantic cutting, drilling and grinding done this evening.


    All the horizontal and vertical stringers are now secured, along with three longerons along the top for dealing with tension force. As there is compression on the bottom caused by the weight cantilevering over the front skid four metres back from the tip of the nose, there will be a lot of compression on the bottom, particularly closer to the skid. The rear former will need to be reinforced with a solid plate/mounting points. More on that when I get there.







  16. sandbagger's Avatar
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    Aug 21, 2017, 5:33 AM - Re: Builds By Baz- Full scale Mk II Colonial Viper #16

    To start building the body of the fuselage in layers, I found some Sikabond foam construction adhesive at Bunnings. Messy stuff, but does the job well and once you understand how it flows, sticks, spreads and behaves generally, you get the hang of it pretty quick.


    The foam I am using is a combination of soft and hard, but when it’s free recycled packaging and produce boxing, one can’t be too fussy. At the end of the day, once shaped, it will be coated in fibreglass anyway. I’ve built it high and then done some rough shape-cutting with the hot wire cutter. The nose was a little tricky because of all the angles, so the next spaces between formers should be a lot easier.


    I think my hot-wire cutter is running a little cool at nearly two feet long, so i’m going to have to hit the calculator and see what I need do do to turn up the heat.


    Later tonight/tomorrow afternoon I might get a chance to shape it more with a rasp and sandpaper. I have shaped foam before in a small scale and it’s surprising how smooth you can get it. Larger surfaces are obviously easier than intricate hand-models.








  17. RPF Premium Member
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    Aug 21, 2017, 9:32 AM - Re: Builds By Baz- Full scale Mk II Colonial Viper #17

    A wire brush is another useful tool for styrene shaping.
  18. joberg's Avatar
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    Aug 21, 2017, 9:32 AM - Re: Builds By Baz- Full scale Mk II Colonial Viper #18

    Excellent work there mate One of our member here is building one out of aluminium...Eager to see your project come to life!
  19. sandbagger's Avatar
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    Aug 23, 2017, 3:57 AM - Re: Builds By Baz- Full scale Mk II Colonial Viper #19

    Today I couldn’t do much while babysitting, but while miss two watched on in the back yard sunshine, dad drew templates and threw balls of screwed up paper at her. What fun dad! Giggling her head off!


    A total of about an hour today was all I could manage. I cut some formers for the second half of the fuselage, finishing at the firewall forward of the cockpit.











    I also spent about five minutes with some 60 grit sandpaper on the nose polystyrene.




    - - - Updated - - -

    Pro Mod said: View Post
    A wire brush is another useful tool for styrene shaping.
    Ok for removing MASSIVE amounts of foam in a hurry and VERY messy.

    - - - Updated - - -

    joberg said: View Post
    Excellent work there mate One of our member here is building one out of aluminium...Eager to see your project come to life!
    Thank you sir. Yes, I discovered him way back when I was a fair way into my first full sized cardboard Viper that I inevitably scrapped. It's been a long time and the man must have a full life as progress has been pretty slow.
  20. RPF Premium Member itsgreg's Avatar
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    Aug 23, 2017, 3:06 PM - Re: Builds By Baz- Full scale Mk II Colonial Viper #20

    sandbagger said: View Post
    To start building the body of the fuselage in layers, I found some Sikabond foam construction adhesive at Bunnings. Messy stuff, but does the job well and once you understand how it flows, sticks, spreads and behaves generally, you get the hang of it pretty quick.


    The foam I am using is a combination of soft and hard, but when itís free recycled packaging and produce boxing, one canít be too fussy. At the end of the day, once shaped, it will be coated in fibreglass anyway. Iíve built it high and then done some rough shape-cutting with the hot wire cutter. The nose was a little tricky because of all the angles, so the next spaces between formers should be a lot easier.


    I think my hot-wire cutter is running a little cool at nearly two feet long, so iím going to have to hit the calculator and see what I need do do to turn up the heat.


    Later tonight/tomorrow afternoon I might get a chance to shape it more with a rasp and sandpaper. I have shaped foam before in a small scale and itís surprising how smooth you can get it. Larger surfaces are obviously easier than intricate hand-models.


    http://i.imgur.com/WxDbEBC.jpg?1


    http://i.imgur.com/3F9LbwW.jpg?1


    http://i.imgur.com/j2sPs4W.jpg?1
    Looking brilliant!
    Using surform tools is a great way to shape your foam, they make really quick work of it. It's what I use for all my patterns, including stuff this sort of size.

    Sent from my SM-N910T using Tapatalk
  21. sandbagger's Avatar
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    Aug 25, 2017, 3:23 AM - Re: Builds By Baz- Full scale Mk II Colonial Viper #21

    I've been researching the instrumentation inside the cockpit, drawing from several sources around the internet. Mostly I'm trying to keep it as accurate as I can, and I really like the cockpit layout in the life size MK II that went up for auction a few years back.

    Many of the instruments are everyday items in modern aviation, along with a few consumer bits of tech for the last 40 years or so.

    Some of the instruments I can source on ebay and the like, others I just have to scratch build. All I needed was a known dimension so that I could scale the rest, using educated guesswork and a Vernier caliper.

    I have an altimeter being sent to me, but these other two instruments I have built from scratch, using the Perspex from a refrigerator crisper drawer, a discarded McDonalds food tray and some printed reference photos hot off the internet.





  22. sandbagger's Avatar
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    Aug 26, 2017, 9:27 AM - Re: Builds By Baz- Full scale Mk II Colonial Viper #22

    Latest article I've written up on all the real-world avionics instruments I am gathering for the cockpit, including warnings about radiation in some instruments.


    http://www.buildsbybaz.com/viper-mk-...ence-pictures/
  23. sandbagger's Avatar
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    Aug 28, 2017, 10:47 AM - Re: Builds By Baz- Full scale Mk II Colonial Viper #23

    Working on some of the cockpit details. Built part tonight.


    Full article here.


  24. George's Avatar
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    Aug 28, 2017, 7:48 PM - Re: Builds By Baz- Full scale Mk II Colonial Viper #24

    This is so cool
  25. sandbagger's Avatar
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    Aug 29, 2017, 5:35 AM - Re: Builds By Baz- Full scale Mk II Colonial Viper #25

    Thanks George.

    After a quick paint, (I know it's not the genuine colour.... yet) I used some cardboard to rough out a dashboard cover unit, then transferred it onto 12mm plywood.





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