pylon500
Well-Known Member
Right, another quick post during lunch...
This wing flew really well, but the rest of the ultralight left a bit to be desired, when it was blown over in a storm, I didn't deem it worth repairing so I stored the wings and scrapped the rest.
Didn't get any photos of the damage, other than the wingtip
;

OK, so modifying the wing involved removing all the trailing edge and fitting a heavier doubler to the trailing edge, a, because the original attach point bracket was showing cracks and, b, this is going to be a folding wing, swinging on the trailing edge like a Kitfox;

The new flaps and ailerons would be remote hinge requiring an arm attached to the wing.
While many will cut out the arm and rivet it to an aligning wing, this then requires a large cut in the skin to allow it through, I simply use a bit of heavy angle and bolted it under the rib after fitting some reinforcing to the fibreglass rib;

This has become my 'go to' method for attaching flaps and ailerons as it only requires a few bolt holes through the lower skin/rear spar, and make them easier to replace should need be.
The previous ultralight was a bit like a Cub in that the aileron controls ran up the strut, but to a belcrank there with a pushrod straight to the aileron. Wanting folding wings and maybe a tidier looking finish, I needed to run the aileron controls out through the wing.
Here is where I cheated, and regretted it thereafter; I used Telemorse cables for most of the control system.
THIS IS A MISTAKE !
These things only belong on boats
Anyway, I now needed a belcrank in the wing, so built a structural box with hardpoints into the rear of the wing;

Now, for those looking really closely will realise the dynamics here aren't quite right and the answer is, the belcrank is neutral when rotated about another 10º anticlockwise, and the pushrod needs to be adjusted shorter.
OK, lunch break over, more plane to build, will detail main wing pickup and fuel tanks next...
This wing flew really well, but the rest of the ultralight left a bit to be desired, when it was blown over in a storm, I didn't deem it worth repairing so I stored the wings and scrapped the rest.
Didn't get any photos of the damage, other than the wingtip


OK, so modifying the wing involved removing all the trailing edge and fitting a heavier doubler to the trailing edge, a, because the original attach point bracket was showing cracks and, b, this is going to be a folding wing, swinging on the trailing edge like a Kitfox;

The new flaps and ailerons would be remote hinge requiring an arm attached to the wing.
While many will cut out the arm and rivet it to an aligning wing, this then requires a large cut in the skin to allow it through, I simply use a bit of heavy angle and bolted it under the rib after fitting some reinforcing to the fibreglass rib;

This has become my 'go to' method for attaching flaps and ailerons as it only requires a few bolt holes through the lower skin/rear spar, and make them easier to replace should need be.
The previous ultralight was a bit like a Cub in that the aileron controls ran up the strut, but to a belcrank there with a pushrod straight to the aileron. Wanting folding wings and maybe a tidier looking finish, I needed to run the aileron controls out through the wing.
Here is where I cheated, and regretted it thereafter; I used Telemorse cables for most of the control system.
THIS IS A MISTAKE !
These things only belong on boats

Anyway, I now needed a belcrank in the wing, so built a structural box with hardpoints into the rear of the wing;

Now, for those looking really closely will realise the dynamics here aren't quite right and the answer is, the belcrank is neutral when rotated about another 10º anticlockwise, and the pushrod needs to be adjusted shorter.
OK, lunch break over, more plane to build, will detail main wing pickup and fuel tanks next...