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  1. Ollie Krause

    Flight Club - Ultralight Build Log

    Hmmmm... This is my understanding of scalloping based on the definition provided in the Poly-Fiber covering manual: "Scallops are troughs that form between the ribs, more so with modern polyester fabrics than classic Grade A Cotton. Although they present no aerodynamic problems, for cosmetic...
  2. Ollie Krause

    Flight Club - Ultralight Build Log

    Sorry but do you have a photo or drawing with more details on this configuration? The ASCII drawings are a bit hard to understand. We were under the impression that scalloping was bad because it deformed the airfoil profile but this patent on leading edge scalloping seems to suggest otherwise...
  3. Ollie Krause

    Flight Club - Ultralight Build Log

    Yeah we abandoned the leading edge spar design a while ago since it easily tore out from the rib when under load. In hindsight, I wish we'd tested some C shaped support washers to reinforce the leading spar attachment but the ribs are plenty strong with the leading spar placed back from the...
  4. Ollie Krause

    Flight Club - Ultralight Build Log

    Thanks! We've come a long ways since that initial post and our fuselage design has changed a TON. Our physics team did a ton of XFLR5 simulations to ensure its dynamically stable and we're simulating it in Fusion360, Solidworks, and GrapeFEA to cross-compare results. Now that school has started...
  5. Ollie Krause

    Flight Club - Ultralight Build Log

    We'll definitely look into fabric stitching some more. I always thought it was used for planes with wooden wings, though, and I'd have concerns that the string would tear through the foam. Anyways, I'll do some more research and report back what I find. In terms of fiberglass cap strips, they...
  6. Ollie Krause

    Flight Club - Ultralight Build Log

    Yeah, we're using fiberglass cap strips as well but I'd be concerned that the Poly-Tak might drip around the edge of the fiberglass and start dissolving the rib. We could use masking tape along the cap strip and then spray a coat of polyurethane varnish on the sides of the ribs. That way the...
  7. Ollie Krause

    Flight Club - Ultralight Build Log

    Hey y'all, It sure has been a while and things are going along nicely for our project. We've started construction and just today laid out all our ribs onto our two spars. We still have a long ways to go but we're hoping to have our wings built before the end of the year! Our blog is a little...
  8. Ollie Krause

    Flight Club - Ultralight Build Log

    Our initial gusset design actually includes the wrap around style gusset but we've since switched over to the separate gusset plate design due to potential bending and fracturing issues with a rigid alloy like 6061 T6. Gauging by the thickness of the gussets y'all seem to be using in your...
  9. Ollie Krause

    Flight Club - Ultralight Build Log

    We were actually thinking of using the CHERRYMAX CR3213-6-2 3/16 diameter rivet for our structural joints which is made of 5056 aluminum and has a rated shear strength of 1480lb. The issue with using stainless steel rivets is galvanic corrosion and we didn't want to have to go through the...
  10. Ollie Krause

    Flight Club - Ultralight Build Log

    If you assemble it by riveting the two internal gusset plates before the external ones there aren't any issues with rivet gun access.
  11. Ollie Krause

    Flight Club - Ultralight Build Log

    Wow those cuts are really impressive. That foam looks really flexible though. Did you need to heat it to take that shape or does it naturally bend? I would have major rigidity concerns if it could bend naturally like that. If it is naturally flexible like that, I assume you're covering all...
  12. Ollie Krause

    AN Bolt Configurator

    Thanks for the suggestion! I just updated the design to have an option to turn off the thread. Since I'm using a free Onshape account, keeping the graphics simple will definitely improve performance.
  13. Ollie Krause

    AN Bolt Configurator

    Yeah I used a couple similar reference sheets when creating my design. These were the two I found most helpful: ANSI Internal Screw Threads Size and Tolerances Table Chart - Engineers Edge https://www.gen-aircraft-hardware.com/images/pdf/an3_thru_an20.pdf
  14. Ollie Krause

    AN Bolt Configurator

    Yeah it's briefly explained in the blog post linked above. All you need to do is select the part configuration in the upper left hand corner and then right click on the "part 1" in the lower left hand corner and click export. It should allow you to choose from a variety of file types and...
  15. Ollie Krause

    AN Bolt Configurator

    Hi Home Built Airplanes Community, Having trouble locating CAD files for AN bolts? Search no further! I created an AN bolt configurator which can model any AN3-AN8 (3/16-1/2") bolt with a length of up to -20 (7.75") within a tolerance of +-0.001". That being said, I haven't tested all the...
  16. Ollie Krause

    Flight Club - Ultralight Build Log

    Thank you for all the great insights! Would you be able to provide some photos or drawings of these two methods? I remember reading about them in some other thread but I was still a little confused on how exactly they worked. What would their primary benefits be over the plywood capped foam ribs...
  17. Ollie Krause

    Flight Club - Ultralight Build Log

    Quick update: now it’s summer, we’re all off school and are regularly putting in 8-12 hour days and making some great progress with our calculations and truss analysis. One issue that we’ve just run into is selecting the proper XPS foam for our ribs. I’ve read through all the HBA threads I could...
  18. Ollie Krause

    Flight Club - Ultralight Build Log

    I skimmed through both NACA reports but they seem to focus more on plywood and truss rib construction and I'm not sure how applicable they could be to our foam and plywood designs. I get the feeling that we just need to eat the $200 freight surcharge and just do the tests ourselves. Unless...
  19. Ollie Krause

    Flight Club - Ultralight Build Log

    Thanks for the generous offer but we're in the San Francisco Bay Area 😆
  20. Ollie Krause

    Flight Club - Ultralight Build Log

    He only mentioned one size that he said slides over a 1" tube. I'd be concerned that larger sizes would weigh too much to be practical for aileron or other large hinges.
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