I have the molds ready to lay up. The idea of using epoxy to surface the MDF didn't really work out as planned. Everything moved around too much after removing them from the CNC. When I went to do cut the final pass, the blanks weren't quite lining up and I had to cut deeper than I wanted. I...
I can see why they had issues with the aluminium hub. The thermal expansion of aluminium is pretty close to double that of steel. Couple that with a smallish taper and the problems reared their ugly head. Be good to see if you can get it all sorted out!
Do you have the steel prop hub on yours?
I dug up a couple of threads on Flying Giants that seem relevant.
This sounds really strange, the torque pulses from the engine firing would be much higher than any torque from the starter. Here is a ZDZ210 being starter with a handheld starter...
I think if the key is shearing with the forces from a handheld starter, then the design of the engine has issues..
I have personally arrived right after an engine start was attempted on a homebuild. All the wires were in place apart from a ground strap from the firewall to the engine. There was apparently quite lot of sparks and smoke from the throttle cable housing when it had to carry all the starter current!
My starters are slightly different, I am using RC brushless motors. So three wires from the ESC run direct to the starter. The ESC is right near the battery so no starter electrons flow through the bolts/mounts at all.
I am putting the engine mounting bolts with the nuts facing forwards. They are easier to install that way and also far easier to inspect. If I had them with the nuts to the rear, they will be a pain to even see, let alone install them on the bolts.
I started on the fairing molds today, I grabbed a couple of offcuts of mdf and laminated them together to make the slab 62mm thick.
While waiting (impatiently) for the glue to dry I cut some templates from 4mm thick pine ply
once the glue had set enough (almost) I cut the slab into some...
I find technical books fascinating, good bedtime reading :D
I blended the airfoil in Rhino and called it good, due to the two end airfoils being sorta 90° to each other on the strut the blend is continuous. I think the upper airfoil alignment makes the most difference.
I took the advice from someone here on the forum (can't remember who sorry) about getting your aircraft supplies while they are still available and went to the local shop and purchased some more bolts and some alodine that I had been putting off for ages.
I have revisited the gear leg fairings...
To answer your questions.
1. The landing gear bow is a really tight fit in the clamps when they are bolted up. There shouldn't be any movement at all between the clamp and the fiberglass. The clamps themselves are bolted to bushings at each end that allow them to rotate slightly.
2. & 3. Each...