Giant Leap Rocketry
 

 

 
Giant Leap Rocketry Components - Composites
 

Aeropoxy: High Grade Epoxy Line

Aeropoxy: High Grade Epoxy LineAeropoxy is a VERY high quality line of epoxy for the most demanding applications. This is the real McCoy. When you want it done right, do it with Aeropoxy. It’s what we use, and it’s the best. Unlike the other system you’ve heard about, Aeropoxy is optimized for aerospace applications. It’s the number one product for home-built aircraft, and we find it unsurpassed for high power rocketry. According to tests by John Coker Aeropoxy was five times stronger than typical hobby store epoxies, and was also stronger than West Systems.

We carry three types of Aeropoxy, which are listed below:

Aeropoxy Laminating Resin:

Ideal for laminating tubes. It's medium viscosity and gives excellent wet-out of fiberglass, carbon and aramid fibers. Special additives are incorporated to promote chemical adhesion to fabrics made with these fibers. Aeropoxy cures completely at room temperature, or can be given an elevated temperature cure. It has no MDA and so it is NOT a carcinogen (unlike other brands). It is tested and endorsed by the Rutan Aircraft Factory, and RAF recommended its use for all homebuilt aircraft applications.

  • The mix ratio of resin to hardener is 3 to 1 by volume.

  • Cure time: approx 1 hour.

  • Tensile strength is 45,170 psi (Properties Derived With 10 Ply Laminate, Hand Lay-up, Style 181 Glass Fabric, 55% Resin Content).

  • Viscosity =900-950 cps

NOTE: Epoxy laminates are far superior to polyester laminates. Epoxy is much stronger, and does not have the noxious, brain-melting odor of polyester. Giant Leap makes its glass nosecones ONLY from Epoxy. Next time you buy a glass laminated tube, or a glass nosecone, be sure it's made with Epoxy and not its inferior cousin, polyster. There's a big difference, and like anything in life, you get what you pay for.

Aeropoxy Structural Adhesive:

For structural adhesion such as bonding fins, centering rings and bulkheads, and wherever else strength is required. It’s the strongest epoxy we know of. So if you want the best, this is it. It has no MDA and so it is NOT a carcinogen (unlike other brands). It’s a straw colored adhesive with a controlled-flow viscosity for good surface wetting, yet minimum run-out from the joint.

  • Mix ratio is 1:1. Cure to handling is 4-6 hours.

  • Full cure at 77 deg F is 18-24 hours.

  • Tensile lap-shear (Alum-to-Alum) at 77 deg is 2700 psi.

Aeropoxy Light Filler:

This is the perfect filler. A two-part paste epoxy patching and filler compound for foam, wood, fiberglass and other surfaces. It is smooth and creamy, so it spreads easily, and can be feather edged without separation. It is a non-sag material that will remain in place even when applied upside down! The resin and hardener of this system are color coded for easy mixing. The resin is white and the hardener is brown, giving a good visual indication of complete mixing with a uniform tan color free of streaks. It has no MDA and so it is NOT a carcinogen (unlike other brands). Aeropoxy Light has low density fillers in it that give it a very low weight. Also, the cured material is very easy to sand, making the finished patch undetectable when covered or painted.

  • No shrinkage

  • Mixed 2:1 by volume

  • Maintains slight flexibility after cure, so you won’t get cracks.

Product

Price

NEW Aeropoxy Laminating Resin
KIT: Pint resin + 1/2 pint hardener

$28.49

Aeropoxy Laminating Resin
KIT: Quart resin + pint hardener

$53.99

Aeropoxy Laminating Resin
KIT: Gallon

$147.99

NEW Aeropoxy Structural Adhesive
KIT: Pint A + Pint

$29.99

Aeropoxy Structural Adhesive
KIT: Gallon

$199.99

Aeropoxy Light Filler
KIT: Quart A + Pint B

$39.99


Flex-Cure Epoxy

Shop-grade epoxy taken to a new level!

Epoxy has been around a LONG time. It’s super strong and dries as hard as a brick. And that’s the problem; Bricks are strong, but they can crack.

So Red Baron improved Epoxy in three ways:

1) They’ve added microscopic rubberized particles to toughen the adhesive. It was developed for the RC guys who needed a super-strong epoxy that resists cracking under high G-loads and vibration. Flex-Cure doesn’t actually flex or bend like plastic; instead the rubberized formulation has just enough microscopic “give” that it doesn’t want to crack – and then break. Cool.

2) Through a propriety process, both the resin and the hardener are made of adhesive, so you get an unbelievably strong bond. Slick.

3) You know how shop-grade epoxies thicken and crystallize with age? Not this stuff. The shelf life of Flex-Cure is measured in years. Nice.

Most shop-grade epoxies come from one main supplier from who-knows-where, but with a different label slapped on.

Flex-Cure is original. Made in America.

Flex-Cure™ 5 min. Epoxy 9oz.
$15.99

Flex-Cure™ 5 min. Epoxy

 

Flex-Cure™ 30 min. Epoxy 9oz.

This epoxy works best for reinforcing fillets on joints. It has the highest strength.
$15.99

Flex-Cure™ 30 min. Epoxy

 

Laminating / Finishing Resin 90 min. Epoxy 9oz.

Red Baron Epoxy Laminating/Finishing Resin epoxy formula is not rubber toughened, but it really doesn’t need to be for this application. Red Baron Epoxy Finishing Resin is designed to work with any weight of fiberglass cloth. It sands well and will not load even fine sandpaper. This allows it to be readied for primer and paint without a lot of elbow grease.
$15.99 Out Of Stock

Flex-Cure™ 90 min. Epoxy

 

Red Baron Cyanoacrylic Adhesive (CA) Thin 1oz.

$5.21 Out Of Stock

Red Baron CA - Thin

 

Red Baron Cyanoacrylic Adhesive (CA) Thick 1oz.

$5.21 Out Of Stock

Red Baron CA - Thick

   

Cyanoacrylate Adhesives (CA)

CAs have become the adhesive of choice for most hobby and household applications. High quality CAs such as Insta-Cure™, when used properly, form bonds that in many cases are stronger than the material that is being adhered. Insta-Cure™ is a highly refined CA which, combined with its freshness, gives a guaranteed 2 year shelf life. CAs are reactive monomers that chemically link (polymerize) when pressed into a thin film. Ideal for tacking fins or other parts into place to get perfect alignment before adding epoxy.

Insta-Cure™ Thin

Insta-Cure™ Thin has a water-thin viscosity that wicks deep into joints by capillary action and cures in a matter of a few seconds. Surfaces to be bonded must be tight fitting and should be held together while you apply the CA around the edges of the seam. At the moment CAs cure, they give off a vapor that can irritate the nose and eyes, so be prepared.

Insta-Cure™ Thin

Insta-Cure+™ Thick

Insta-Cure+™ Thick is a higher viscosity CA for loose fitting joints in which the adhesive must bridge gaps. Normally, the thicker CA is applied to one surface and then the parts are held tightly together for about 5 to 15 seconds. For large surface areas, including those with close fitting joints such as laminations, Insta-Cure+™ should also be used. To prevent premature curing, don’t spread the glue into a thin film. Lay down a serpentine bead with about 1" separations on one surface, then assemble the parts, letting the pressure spread the CA out.

Insta-Cure+™ Thick

   

Product

Price

Insta-Cure™ Thin - 1 oz.

$6.29

Insta-Cure+™ Thick - 1 oz.

$6.29

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Mega-Foam

Mega-Foam a premium foam at a volume discount! Mega-Foam a premium foam at a volume discount!

We discovered expandable foam years back from a group of level-2 and -3 flyers in California. It¹s a two-part urethane, closed-cell expandable foam that fills in the fin tab / motor tube area, nosecone, or anything else you can think of. We've used it to reinforce a crimped airframe. Easy to use; Just mix the two-part foam and pour into the cavity. It starts to expand in less than a minute. It¹s high-density structure helps hold fins into place, and provides rigidity to other structures like nosecones, with virtually no cost in weight. The foam does not require oxygen to cure. Special heat-resistant formulations. Expands approximately 20 to 30 times it's size.

Product

Price

One Quart Kit 
(Pint A; Pint B. May be slightly less to allow for expansion)

$29.99

2 Quart Kit BEST VALUE! 
(Quart A; Quart B. May be slightly less to allow for expansion. LONG shelf life!)

$49.99

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Easy-Glas Sock

Finally there's an easy way to glass your tube - - with the Easyglas Sock

Click images for larger view

 

Finally, an easy way to fiberglass your bodytube! The Easyglas Sock is a stretchy sleeve that fits over your airframe to make fiberglassing a breeze. Traditional fiberglassing methods are tricky, and involve wrapping cloth around a tube. The downside of this old approach is that it's time consuming, really messy, frustrating and, worst of all, leaves an overlap ridge that has to be sanded down. In short, it's a royal pain!

Finally there's an easy way to glass your tube - - with the Easyglas Sock.

The Easyglas Sock is not fiberglass, but is made of a material that readily absorbs resin and adds structural strength. We've tried it and it works beautifully. Best of all, it finishes easily. The Easyglas Sock is about as thick as 3 or 4 oz fiberglass cloth.

Here's the simple procedure:

  • Slide Easyglas Sock over dry airframe and tie the loose ends with twist-ties.

  • Mix your resin, and apply thoroughly over the Easyglas Sock. Squeegy excess material and rotate tube occasionally while resin cures.

  • Once cured, lightly cut down high spots with sandpaper, then prime with several coats of extra thick filler primer (available at department stores). Be sure to sand between coats of primer.

That's it!! Trim the ends and you're ready to paint!
Finally...lamination for the rest of us!!

For additional strength Kevlar® Sock (below) can be used underneath the Easyglas Sock.

Size

Price per foot

Easyglas Sock small diameter for 4" airframes only
(order 1.5 times length of airframe)

 $1.67

Easyglas Sock large diameter for 5.5" to 6.0" airframes
(order twice length of airframe)

$2.09

Easyglas Sock Extra large diameter for 7.5" airframes and larger
(order twice length of airframe)

$2.51

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Airframe Sock of Kevlar®

Dave Rose puts the Kevlar® Sock onto a 6" and 7.5" diameter airframe. He used a nosecone to taper on the sock. He then wet it out with fiberglass.

 

Kevlar Sock

A new stretchable Kevlar® sleeve made of 100% pure Aramid Kevlar® that slides onto your airframe.

Laminating your tube is rewarding. But while fiberglass is easy to work with, Kevlar® cloth is costly and tricky. NOT ANY MORE!

Now reinforcing your tube in Kevlar® is like putting on your socks. Just slide the Airframe Sock of Kevlar® on the tube. Because it’s stretchable - - like your socks - - it conforms to the tube and compresses down to hold in place (vacuum bagging optional but not necessary). And since there’s no seam overlap, there’s no bump to sand. Because Kevlar® can’t be finish sanded, you’ll still need to cover the Airframe Sock of Kevlar® in a thin layer of glass. We now have two different sizes of Airframe Sock of Kevlar®. The SMALL stretches over 54mm and 2.56" tubing, whereas the MEDIUM stretches from 3" to 3.9" tubing. It adds between 1/64” and 1/32” to wall thickness.

Now in Two Sizes!!!
SMALL for 54mm and 2.56
MEDIUM for 3" and 3.9"



 

Size

Price per foot

Airframe Sock of Kevlar® - Small
(order 1.5 times the length of the tube for up to 4” in diameter, and 2.0 times the length for 6”. E.g., for a 3” diameter tube four feet long, allow six feet of sock. For a 6” tube that is 4 feet long, allow eight feet of sock).

$3.49

Airframe Sock of Kevlar® - Large
(order 1.5 times the length of the tube for up to 4” in diameter, and 2.0 times the length for 6”. E.g., for a 3” diameter tube four feet long, allow six feet of sock. For a 6” tube that is 4 feet long, allow eight feet of sock).

$3.99

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Fiberglass Laminating Cloth, Satin Finish

Fiberglass Laminating Cloth, Satin Finish

 

Conforms easily to contoured surfaces and compound curves. Great for tube lamination and for fin layups. Used extensively in the home-built aircraft industry.

 

Fiberglass Laminating Cloth, Satin Finish

Product

Price per Yard

3 oz satin weave 50" wide

$9.97

10 oz satin weave 52" wide

$13.64

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Brushes

1/2" wide Shop Brush

Great for spreading epoxy in small areas.

Heavy duty horse hair bristles handle everything from glue to oil to flux. 7/8" bristle length Metal tubular handles with 6-1/8" length

1/2" wide Shop Brush

1" Industrial Grade Chip Brushes

Ideal all-around brush. Used in laminating, adhesive application, fiber glassing, cleaning, and touch-up work. Rugged construction with pure china bristle and sturdy hardwood handle.

1" Industrial Grade Chip Brushes

2" Industrial Grade Chip Brushes

Ideal all-around brush. Used in laminating, adhesive application, fiber glassing, cleaning, and touch-up work. Rugged construction with pure china bristle and sturdy hardwood handle.

2" Industrial Grade Chip Brushes

   

Product

Price

1/2" wide Shop Brush

Pack of 4 $1.04

1" Industrial Grade Chip Brushes

$0.62

2" Industrial Grade Chip Brushes

$0.83

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Mixing Cups

Graduated Mixing Cups 4.5 oz.

 

For accurate mixing of Epoxies, foams and other liquids.

 

Mixing Sticks

 

High quality tongue-depressor type.

Graduated Mixing cups
   

Product

Price

Graduated Mixing Cups 4.5 oz

Pack of 4 $2.23

Mixing Sticks

Pack of 25 $1.19

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Nitrile Gloves

Superior Protection from Most Substances Much better than latex for resisting chemical solvents and oils. Conforms to user's hand the longer they are worn, providing support and reducing hand fatigue.

CAUTION: Prolonged skin contact with epoxy can be harmful to your health. We’ve had customers who are no longer able to handle epoxy because of skin-hypersensitivity. Don’t take chances; wear gloves when handling epoxy. Besides, for a few pennies, gloves save you from having to wash your hands with thinner - - which is another toxic substance.

Nitrile Gloves

 

Product

Price per Pair

Nitrile Gloves

$0.75

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Combination Sets (Save$)

Combination Sets for BIG SAVINGS!

 

Mixing Set (SAVE 27%)

  • 4 mixing sticks

  • 4 mixing cups

  • 4 pairs of Nitrile Gloves

  • 4 shop brushes 1/2"

  • 4 brushes 1"

  • 4 brushes 2"

Epoxy and CA Combo Set (SAVE 20%)

  • 5-Minute Epoxy

  • 12-Minute Epoxy

  • 30-Minute Epoxy

  • Laminating Epoxy (all are 8 oz set)

  • FLASH thin CA 1 oz.

  • FLASH thick CA 1 oz. 

Product

Price

Mixing Set

$6.82

Epoxy and CA Combo Set

$47.67

Out Of Stock

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