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Electric Belite!

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Farfle

Well-Known Member
Joined
Dec 31, 2015
Messages
80
Location
Redmond, OR
Hello all, I purchased a Belite Ultracub in Feb of this year, and now that I have some progress, I am posting up some pictures, Enjoy!

Specs:
Motor: Zero ZF75-5
Hp: 41hp cont, 54hp 5min
Tq: 78 ft/lbs
Base speed; 5808 RPM
Reduction: 65-30 8mm toothed belt drive (2.2:1)
Controller: Sevcon Gen4 size 4
Battery: Farasis 29Ah pouch in 28S4P configuration for 12.0 Kwhr of storage

Boxes! Very professionally packaged, and Old dominion freight did an excellent job of treating the boxes nicely from Wichita to Moscow, ID.





Clecos everywhere!




Cabin and tail temporarily mated:




Temporary landing gear:



More pics to follow
 

Farfle

Well-Known Member
Joined
Dec 31, 2015
Messages
80
Location
Redmond, OR
Reduction drive machining:



Propshaft bearing tube. .065 wall 2.5" 4130 tubing holding a pair of 2" OD Tapered roller bearings.



Prop mount flange:



DIY rotary welding table makes good results! 4130 shaft welded to 4130 flange with 4130 filler rod. Will be sent out for heat treat and shot-peening.








Mount flanges attached:



Finished Re-drive:





Spring-gear painted and installed:


 
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Farfle

Well-Known Member
Joined
Dec 31, 2015
Messages
80
Location
Redmond, OR
Wing coming together:


Wing temporarily mounted up! Looking more like an airplane at this point!



Door!






Battery module one of two installed:




Battery module two of two lives behind the seat:




Both packs, we will see where the CG ends up. The front pack has some fore and aft movment, and the rear pack could be rotated 90 degrees if weight needs to move rearward.

 

saini flyer

Well-Known Member
Joined
Mar 12, 2010
Messages
468
Location
Dallas, TX
Great project. Looking forward to see the first flight report. Good luck

The Zero info I am providing is a few years old but good for reference.
I dont think you can just buy a powertrain from Zero anymore. You need to be a dealer.
Zero motor and controller spec sheet.jpg


Zero Battery pack information.jpg


Zero complete powertrain kit.jpg
 

Authmion

Active Member
Joined
Oct 24, 2016
Messages
28
Location
Leland, NC USA
Cant wait to see more progress! Especially with the Zero motor. I've heard of people using them, but never seen them in action. I also want to do electric.
 

Farfle

Well-Known Member
Joined
Dec 31, 2015
Messages
80
Location
Redmond, OR
Got the first round of thrust testing and burn-in complete! Forgot to edit an amperage limit after a last minute firmware upgrade, so I left about 20% more power on the table. Will be headed back for more testing this weekend or next. Thrust was 600+ lbs at 9 degrees, but thats pitched for ~40mph. thrust decreased to 220 lbs at 14 degrees, so we settled at 12 degrees and 280lbs of thrust.

 
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Victor Bravo

Well-Known Member
Joined
Jul 30, 2014
Messages
7,766
Location
KWHP, Los Angeles CA, USA
Those numbers are about the best case I've ever seen for a controllable pitch propeller!

600 pounds of thrust for takeoff on what is probably a 600 pound airplane, is just too good to pass up. You can give Dead Stick Steve a run for his money, by taking off uphill from the same hilltop he takes off downhill. THAT will be a "mic drop" moment! The youtube video revenue will pay for your airplane :)

But if you can have a high pitch position that allows you to use a lot less current in between those VTOL maneuvers, that would give you some usable range for the type of back country flying that this aircraft will be used for.
 

Farfle

Well-Known Member
Joined
Dec 31, 2015
Messages
80
Location
Redmond, OR
Those numbers are about the best case I've ever seen for a controllable pitch propeller!

600 pounds of thrust for takeoff on what is probably a 600 pound airplane, is just too good to pass up. You can give Dead Stick Steve a run for his money, by taking off uphill from the same hilltop he takes off downhill. THAT will be a "mic drop" moment! The youtube video revenue will pay for your airplane :)

But if you can have a high pitch position that allows you to use a lot less current in between those VTOL maneuvers, that would give you some usable range for the type of back country flying that this aircraft will be used for.

Sadly its only a ground adjustable prop. Variable pitch would be awesome, although i am not sure if anyone makes a small variable pitch prop in this size range. It would be pretty easy to implement though, as the reduction drive could easily have a hollow shaft.
 

Victor Bravo

Well-Known Member
Joined
Jul 30, 2014
Messages
7,766
Location
KWHP, Los Angeles CA, USA
Ivoprop and others have built electric variable pitch propellers. No hydraulics, no oil passages, nothing. Just electricity.

Beech-Roby propellers are still around, you might pick up a used one of those and put in newer composite blades on their hub. I believe they are mechanically (manual) operated.
 
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