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    Wing Spar - design / bonding pultrusions

    Because a bellcrank looks like what I made* I never really thought about this. Seems like something that'd be fun to play around with in some kind of generative design environment and see what the computer thinks it should look like. I bet whatever the result is would really upset an inspector...
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    Wing Spar - design / bonding pultrusions

    Definitely takes ages! I used a 1/8 single flute carbide slot mill at 18k rpm on .4mm DoC slotting, 1mm DoC clearing all at 1000mm/min except for boring down in tight holes which is half that. The reason there's so much 'glitter' is I haven't bothered to hook the vaccum to the front of the...
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    Wing Spar - design / bonding pultrusions

    While I was in the wing I was thinking about bell cranks... So I got the old CNC running and made some to play with. What size bellcrank is a good compromise? I was thinking a nice 75mm arm. And 3mm 6082 rather than two bent bits of 1.5mm. I haven't quite worked out how to properly secure the...
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    Wing Spar - design / bonding pultrusions

    As a proud englishman I am sad to have to say two things: 1. The French design some VERY nice aeroplanes. 2. It's really embarassing I don't speak much French - why does wingtip auto-translate to 'salmon'?
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    Wing Spar - design / bonding pultrusions

    Thank you everyone - super-helpful as always. Adding about 200g of foam makes my whole spar design really, really simple to build. I really love the Gazaile 2 but the way the wing joiner hardpoints are made always surprised me - obviously it works, and is really simple but it seems sort of...
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    Wing Spar - design / bonding pultrusions

    Do you mean phenolic instead of the ply?
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    Wing Spar - design / bonding pultrusions

    And this for the spar overlap - full width foam with ply hardpoints with brass bushings all wrapped in a lot of carbon to take the large shear loads between the pins. Assemble wings on jig, line everything up, drill slightly oversize, insert bushings with a lot of mumpe and pins in place, wait...
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    Wing Spar - design / bonding pultrusions

    So something more like the attached? 10mmx1mm pultrusions pre bonded for the cap, 10mm thick core running full depth and all wrapped in a single bit of carbon (more wraps of carbon where needed). I'd not seen the KR Super 2 website before - that's got some interesting stuff!
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    Wing Spar - design / bonding pultrusions

    I have a quick question: is the attached basically the best / most foolproof way of doing things? Red - Pultruded carbon strip spar cap already bonded. Green - PVC Foam Black - continuous wrap of carbon overlapping for an inch or so in the middle of the shear web. And also -bonding pultruded...
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    Fisher Flying Products Announces New Electric Propulsion Systems

    As someone that flies gliders in the very fickle conditions of the UK the idea of e-soaring is a very attractive one. There's always a gap that's a bit too big even with my 40+ to one glide ratio. That's before you hit the inconvenience/potential danger of not getting home.
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    QC Question...

    And as to the what's and why's... Putting fully extended brakes away also puts the 15 degrees of flap away. Which I didn't consider while trying to arrest my excessive sink rate. Good job it's a grass field or there'd be more than just the seat pan to fix! I try to make these mistakes just the...
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    QC Question...

    Thanks everyone. Had to start over! Failed to seal the back properly and air displaced resin around the original crack (sanded to almost nothing). Would have been fine if I was sensible and just did an open layup. Your replies are almost like a textbook that opened at exactly the right problem...
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    QC Question...

    Opinions wanted please! Does this repair look resin starved or fine?
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    Exian's composite planes

    These are things of beauty! Well done! MOre pictures of construction please as it's all both inspirational and informative.
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    Refinishing gliders

    Or there's something like this to maybe add a few years: http://soaringcafe.com/2014/04/how-to-sand-your-glider/ plus some more aggressive sanding to the leading edge where the gel has blistered all along the glue line. I suppose I should take some photos...
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