Fabricating the Exhaust Stacks

To begin fabricating scale exhaust stacks for the cowl of my SBD, I started out by cutting a block out of standard white styrofoam. I cut the piece to a size that would allow me to shape out both stacks together, end to end, like "half a doughnut." Next I began sanding the block to the targeted shape, then skewered onto a piece of music wire. Next, I began building up a number of layers of heavy glass onto it, using standard quick-drying epoxy for resin.

Once the epoxy had fully cured, I was able to cut the ends of even, then use a paper towel soaked in Acetone to "melt out" most of the styrofoam from inside the stacks. Lastly, I added a few more coats of epoxy on the inside and sanded everything out smoothly.

Moving on, I now cut the shape down into two small "elbow stacks" to work on them individually. Repeatedly test fitting them into holes I cut out of the cowl, I further refined the shape and size of each stack. Once satisfied with the stacks, I cut two light ply rings that I glued to each stack as a backplate to fit up to the inside of the cowl.

I'll hold off on gluing them in place permanently until after the plane has been painted. I did however proceed with painting the stacks with hobby enamels and weathering them with waterbase hobby acrylics. Lastly I clearcoated them with clear acrylic.




"Modifying the Cooling Louvers"