My extraordinary plane build ...

Discussion in 'Member Project Logs' started by cheapracer, Apr 5, 2016.

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  1. May 2, 2017 #101

    cheapracer

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    Test Flap made with tin turned out fine, real ones tomorrow.

    Sitting next to Aileron here .....



    Flap 1.jpg

    Flap 2.jpg

    Flap 3.jpg
     
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  2. May 2, 2017 #102

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  3. May 3, 2017 #103

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    So after the tin test, lasered up the Flaps this morning and 2 hours later had 2 flaps to make the basic Aileron/Flap sets.

    Now to the operation levers for both so I can think about closing up the wings ..


    ailflaps 1.jpg

    ailflaps 2.jpg
     
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  4. May 5, 2017 #104

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    Just a minor update, the Aileron quadrants or lever, whichever you prefer, are done ...

    quadrant 1.jpg
     
  5. May 8, 2017 #105

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    .. and just positioning and aligning the Ailerons today.

    Start making the linkages tomorrow.



     
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  6. May 9, 2017 #106

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    So figured a base line for a fast, easy, super cheap Aileron linkage, off to the laser shop in the morning, weld it up and see what I have to push and shove to get things working as desired.

    It's one of the very few welded parts in the beast. .. and yes, differential Ailerons.



    aileron linkages 0.jpg
     
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  7. May 10, 2017 #107

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    So this is the roughed out version using SCRAP RUBBISH laying around the shop, that includes the tubing. NOT indicative of the final product, just using it to measure throw, angles and clearances.

    After this, I modified the action a little, very happy with the differential action, and tomorrow I will make a decent looking, smaller and lighter unit closer to what will be used.



     
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  8. May 11, 2017 #108

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    So today bellcranks that are leaner, meaner that I named "Katrina".

    Because "Bob" didn't rhyme.
     

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  9. May 11, 2017 #109

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    Dubble Trubble
     
    Last edited: May 11, 2017
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  10. May 12, 2017 #110

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    So today's efforts.

    First a new Aileron quadrant to tie in with the final bellcrank layout, and a little bit of effort into getting weight out of it.


    aileron quadrant.jpg



    Now, good news for some of the lazy, useless, indolent, apathetic, inert, languorous, lethargic, listless, sleepy, sluggish, torpid sods out there who don't want to drill holes.

    Because of the work on the bellcrank, I damaged the adjoining number 6 rib, so had to make a new one. I spent a whole 20 minutes of my incredibly precious time for you mentioned above, working out how to perfect matched holes for the non-linear curve to suit the pre-formed rib flange.

    The parts arrived on my bench and it took me 2 minutes and 7 seconds to assemble it including stopping to have a swig from my bottle of drink (true story).

    So as some of you requested, I present: matched hole ribs ...


    rib 61.jpg

    rib 62.jpg

    rib 63.jpg

    rib 64.jpg

    rib 65.jpg


    The finish is superb, far better than the hand drilled, **** you to hell Laser Beam, the Arch Enemy of Luddites the World over!
     
    Last edited: May 12, 2017
  11. May 13, 2017 #111

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    Because of a well thought out complete system, I was quite pleased with myself that my 'clever hidden' counterweight system not only worked as planned, but relies on about 1kg/2.2lbs rather than the 2/4.4lbs or 3kgs/6.6lbs that many other craft use per side.

    I'll show you and explain when it's all properly finished, but today I temporarily tested the setup using some lead for weight gotten from a local fishing shop melted into a mold (not the final method). Here's a shot of my temporary industrial foundry I set up today, and the most critical tip I can give to homebuilders: Wait until the Wife goes out! ...



    lead melt.jpg


    I also believe my system is superior to this guy's 3kgs of lead shot in a bucket hanging on a rope, imagine the drag on it! He could at least put low drag aero tubing over the ropes ...

    counterweight.jpg
     
  12. May 14, 2017 #112

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    Nice ...

     
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  13. May 15, 2017 #113

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    So after all my mucking around with testing weights with melted lead in my tubes, I went out and bought a bar of round brass and sized it up accordingly, with a thread at one end and made my Aileron link.

    brass 1.jpg


    What I have done is made a long lever arm from the Aileron pivot and simply used the weight as part of my link to apply weight to the lever arm, killing 2 birds with one stone.


    brass 2.jpg


    Also good news is the Ailerons are easily adjustable for both reflex and roll trim, and other stuff.
     
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  14. May 23, 2017 #114

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    I decided it's about time I did the rudder.

    Couldn't have been easier and it was a great feeling of starting completely from scratch to finished product feeling I have my processes completely under control now.


    3D rudder.jpg

    2D laser.jpg

    rudder 1.jpg
     
  15. May 24, 2017 #115

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    Chipping away a bit more today, rudder is basically fully operational now sans operating cables, and later some nice upper and lower covers..
     

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  16. May 29, 2017 #116

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    Rudder on and tested for mounting, clearances, motion etc - all good.
     

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  17. Jun 8, 2017 #117

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    The 'Simple Stick' is working very nicely as ugly as the prototype currently is.

    simple stick 2.jpg

     
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  18. Jun 13, 2017 #118

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    Having gotten the ailerons to a point I'm happy with, tomorrow I going to tighten everything up with the control system and actually start looking at skinning the wings.

    Last week I did laser a bit of sheetmetal to make sure the 2D computer measurements match real life, they didn't and it was a real head spin for an hour or so until I realized what was going on. All good now.

    And just for kicks, then there was a difference between the left and right aileron's angles that had me going until I remembered after 15 minutes of remeasuring everything twice I actually mounted the control stick 15mm (5/8") to the right of aircraft center! Ahhhh!

    Might actually look something like a plane by next week.
     
  19. Jun 16, 2017 #119

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    As I said, starting the skinning process, all pre-matched hole. D-nose tomorrow.

    wskin 1.jpg
     
  20. Jun 17, 2017 #120

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    Milestone reached today as the first permanent wing skin begins to be attached ..
     

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