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  1. #601

    RE: Dirty Birdy ARF

    Ralph,

    I use a torch to heat it up until it’s easily bendable.

    I use metal bars inside and or on the outside of the tubing to make it bend.

    I use oak hardwood pieces with a bored hole to clamp in the vise as not to mar the header.

    Here are the two torches that I use; if you’re not careful with the heat from the torches you can melt the aluminum.
    I have on occasion ruined a header or twousingthis process ............................


    ORIGINAL: Ralph White

    Paul, How did you go about re-bending the header? I was afraid the header might kink if I tried re-bending it.
    Ralph White
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    Paul Pappas, AMA 42520
    www.NECPO.org

  2. #602

    RE: Dirty Birdy ARF

    Ben, the header ends up being too close to the fuse so I needed to tweak it so the pipe could be mounted on the side of the fuse.

    >>

    I put in a balsa block and contoured it for the header fit, then glassed over that. I also contoured the back of the block so you can still fit the stock tank,

    but I’m using a 2 oz tank in the location of the stock tank with a 16oz behind that. The NovaRossi 61 is a very thirsty engine when running high rpm.


    ORIGINAL: Strega1

    Hey Paul

    Thanks for the pics and the info on the DB and Rossi. I'm at a loss on the header. Why did you have to bend it? Was there an obstruction? Does all this grinding weaken the firewal? How are you going to reinforce it and with what? When you are done with this project, please furnish more pics and a blow by blow on how you did this particular cut to the firewall. I'll be doing the same with my project, either the side exhaust w/ Performance Specialties tune muffler, or the RE Rossi and modifications. I'll furnish plenty of photos

    Thanks for all the info and the photos.

    Ben Cubillos
    El Paso, Texas
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    Paul Pappas, AMA 42520
    www.NECPO.org

  3. #603
    PatternPilot's Avatar
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    RE: Dirty Birdy ARF

    Paul,

    Looks good..... with the header tank are you going to put the main tank on the CG ?

    scott
    Scott Anderson - CPA #2 - www.ClassicPatternAssociation.com - Team Airtronics SD10G - NSRCA 529 - VRCS 236

  4. #604

    RE: Dirty Birdy ARF

    Scott, I’m still working out my fuel system on the Test stand, but aiming to put the 16 oz close to the CG if possible with my setup.

    >>

    “HEADER UPDATE”

    Even after tweaking the stock NovaRossi header, the clearance that I was looking for could not be achieved, so I cut the exhaust flange off a strait header and bent a new pipe and welded it together. Now I’m back in business, just need to clean up the weld and polish her up. Everything good to go as far as the exhaust.

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    Paul Pappas, AMA 42520
    www.NECPO.org

  5. #605

    RE: Dirty Birdy ARF



    header done!!, this has put me behind schedule but worth the power the NOVAROSSI 61produces

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    Paul Pappas, AMA 42520
    www.NECPO.org

  6. #606

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    RE: Dirty Birdy ARF

    Did you TIG the header together?

  7. #607
    PatternPilot's Avatar
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    RE: Dirty Birdy ARF

    looks like paul is going into the header bussiness.....
    Scott Anderson - CPA #2 - www.ClassicPatternAssociation.com - Team Airtronics SD10G - NSRCA 529 - VRCS 236

  8. #608

    RE: Dirty Birdy ARF


    Ben, more pics of the glassing and how it turned out before paint.

    It came out better than I thought for working with a painted fuse, TAPE is your friend!!

    I used UFO thin and some accelerator to do the glassing instead of epoxy, very quick and light process.

    ORIGINAL: Strega1

    Hey Paul

    When you are done with this project, please furnish more pics and a blow by blow on how you did this particular cut to the firewall. I'll be doing the same with my project, either the side exhaust w/ Performance Specialties tune muffler, or the RE Rossi and modifications. I'll furnish plenty of photos

    Thanks for all the info and the photos.

    Ben Cubillos
    El Paso, Texas
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    Paul Pappas, AMA 42520
    www.NECPO.org

  9. #609

    RE: Dirty Birdy ARF


    Hey Jeff,

    Yes this one was done by Heli Arch/TIG, but I’ve also done them with the aluminum welding rods.


    ORIGINAL: JeffH

    Did you TIG the header together?

    Scott, need a lot more equipment for such an endeavor.

    I can do them if I run out of options.

    I just need a more precision bender which I finally have found though.


    ORIGINAL: PatternPilot

    looks like paul is going into the header bussiness.....
    Paul Pappas, AMA 42520
    www.NECPO.org

  10. #610

    RE: Dirty Birdy ARF

    NovaRossi REX CX61 installation pics.

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    Paul Pappas, AMA 42520
    www.NECPO.org

  11. #611

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    RE: Dirty Birdy ARF

    I have flown my Phoenix 7 arf with the 65 OS and standard muffler. Today's engines are so much better that I really don't think I need a tuned pipe. Goes fast and flys great with eflite electric retracts.

  12. #612
    jet22b's Avatar
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    RE: Dirty Birdy ARF

    pitstop000
    Very nice setup!!! I wish I still Had my Rossi CX61.[]
    Have fun and we want a flight report, please!!
    Sonny
    aka
    jet22b
    Spitfire Brotherhood #12
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    Great Planes Citabria DLE 35RA CC

  13. #613
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    RE: Dirty Birdy ARF

    Paul, What ball links are you using on the throttle and mixture controls at the engine end? How are they connected to the cables?

    Ralph
    Original AMA # 5646
    P-51 Mustang Brotherhood # 26

  14. #614

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    RE: Dirty Birdy ARF


    ORIGINAL: Harv2828

    I have flown my Phoenix 7 arf with the 65 OS and standard muffler. Today's engines are so much better that I really don't think I need a tuned pipe. Goes fast and flys great with eflite electric retracts.
    Harv, how did you mount the E-Flite nose gear? I have read that people were having problems with the gear electronics failing because of vibration.

    Bruce
    Bruce L. AMA# 54227
    Ultra Sport Brotherhood #15

  15. #615

    RE: Dirty Birdy ARF

    Thanks Sonny,
    "Flight Report" sure, that's comming up.
    This NovaRossi DB and the otherOS powered DB will both be at the NECPO event onSept 8, 2012 in

    Farmington CT


    Any qualified pilot will have a chance to fly either one at the event.

    ORIGINAL: jet22b

    pitstop000
    Very nice setup!!! I wish I still Had my Rossi CX61.[]
    Have fun and we want a flight report, please!!
    Sonny
    aka
    jet22b
    Ralph, I used Sullivan's #508 flexible cable which includes the brass couplers with 2-56 threads, just silver solder them on and they fit the ball links.
    For the Ball links I use the Dubro 181 for the trotle and the Dubro 190 on the mixture control, they also come with solder on 2-56 couplers.

    ORIGINAL: Ralph White

    Paul, What ball links are you using on the throttle and mixture controls at the engine end? How are they connected to the cables?

    Ralph
    Paul Pappas, AMA 42520
    www.NECPO.org

  16. #616

    RE: Dirty Birdy ARF

    FINALLY DONE !! More pics Guys.
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    Paul Pappas, AMA 42520
    www.NECPO.org

  17. #617
    jet22b's Avatar
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    RE: Dirty Birdy ARF

    Again, very sweet setup!! Thanks for sharing!!

    Sonny
    aka
    jet22b
    Spitfire Brotherhood #12
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  18. #618
    AllTheGoodNamesAreTaken's Avatar
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    RE: Dirty Birdy ARF

    Paul, that looks fantastic!!!
    Don\'\'t just stand there, go get some glue!

  19. #619
    KLXMASTER14's Avatar
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    RE: Dirty Birdy ARF

    Paul,
    Buckle up buddy! That thing is going to haul *****!! I had the opportunity to fly a ten pounder with the NovaRossi up front. Didn't feel like ten pounds to me. Best of luck on your maiden. Very clean job, by the way.
    -Robert
    West Coast Regional Director- Classic Pattern Association
    Team Tailwinds
    Ultra Sport Brotherhood #162

  20. #620

    Join Date
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    RE: Dirty Birdy ARF

    Hey Pitstop000,

    You have INCREDIBLE skills..... How are you going to attach the pipe to the fuse for support, or are you?

    Thanks
    David
    Fly Safe and Have Fun ! ! !
    Ultra Sport Brotherhood #22

  21. #621

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    RE: Dirty Birdy ARF

    Paul,

    What spinner are you using?

    Thanks, Gene

  22. #622

    RE: Dirty Birdy ARF

    Thanks Guys for all the compliments!

    >>

    “Pipe mount”

    >>

    I’m using a regular DaveBrown tune pipe mount, not the Hush-clamp, I don’t trust O rings for retaining a pipe and rather strap it with a metal zip tie.

    >>

    “Spinner”

    Custom moded 2 ¼ Tru-Turn FAI spinner.

    >>

    Here are some pics of the OS 65 AX powered Dirty Birdy, “BD 1”

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    Paul Pappas, AMA 42520
    www.NECPO.org

  23. #623
    jet22b's Avatar
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    RE: Dirty Birdy ARF

    pitstop000,
    Another sweet setup!!! Can I come and hangout in your worshop??? Now that I see how the OS 65AX look in this bird, I will have to make the move get get DB #2, ( when Tower get them back in-stock,), I will go with that setup. I just my buy two DB's and set up #3 with the Evo 60nx with a Jett pipe. I have that setup in a Hangar 9 Jackal and its a blast!!!
    Thanks, again for sharing!!!
    Sonny
    aka
    jet22b
    Spitfire Brotherhood #12
    P-40 Brotherhood #52
    Great Planes Citabria DLE 35RA CC

  24. #624

    RE: Dirty Birdy ARF

    Anytime Bud!
    ORIGINAL: jet22b

    pitstop000,
    Another sweet setup!!! Can I come and hangout in your worshop???
    Sonny
    aka
    jet22b
    Paul Pappas, AMA 42520
    www.NECPO.org

  25. #625

    RE: Dirty Birdy ARF

    Going back to wing joiner, forgot to post this at the time.

    >>

    Here are pics of it all done, used G-flex epoxy for putting it together. One to one by volume or 1.1 to 1 by weight, this epoxy can take flex without cracking like other epoxies once stressed. This was the heavier of the 2 wing joiners so it went into the OS powered Dirty Birdy.

    >>

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    Paul Pappas, AMA 42520
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