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The fins for the flight fin can were made out of a 1/8" sheet of G10, with a phenolic leading edge made from 1/4" phenolic sheet. The fin core is G10 and had a tab cut into its leading edge, and the phenolic piece (with a slot cut into it) fits over the leading edge of the G10 fin. Below were the steps used to manufacture themand assemble the fins. All of the machining was done in Gelb (Todd's shop in the basement of the Unified Lounge).
Materials Required:
- 1/8" sheet of G10 (INSERT LINK)
- 1/4" sheet of phenolic (INSERT LINK)
- 15 degree end mill (https://www.mscdirect.com/product/details/04153326)
- 1/16" cutting bit (for mill)
- West Systems epoxy (CHECK)
Part One: Waterjet G10 Fin Core
- Make a DXF drawing of your fins, keeping in mind the size of the sheet you have and the size that the waterjet can fit. Arrange the fins such that they fit close together without being too close (leave around 1/2" space) and add at least two extra fins. You'll need one extra fin to position the fins while milling the tab, and at least one other extra in case something goes wrong.
- Save your fin file (.dxf) onto a USB key
- Follow the procedure for waterjetting specific to the waterjet you're using. Make sure the cutting edge is on the outside of the part, or the fins will be slightly too small.
Make DXF file
Turn on waterjet
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