Notices
Electric Pattern Aircraft Discuss epowered pattern aircraft in this forum

Amadeus

Old 06-28-2015, 12:01 PM
  #1  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 421
Gallery
My Gallery
Models
My Models
Ratings
My Feedback
Default Amadeus

Time for a new F3a model. Electric this time. Working name is Amadeus. The fuselage will be molded and the wings balsa on foam. I will cover the molding process, which is something not seen here much.
Attached Thumbnails Click image for larger version

Name:	Screenshot_3.png
Views:	327
Size:	154.9 KB
ID:	2106188   Click image for larger version

Name:	Screenshot_2.png
Views:	448
Size:	12.7 KB
ID:	2106189  
RodneyFord is offline  
Old 06-28-2015, 12:42 PM
  #2  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 421
Gallery
My Gallery
Models
My Models
Ratings
My Feedback
Default

Here are some dimensions.
Attached Thumbnails Click image for larger version

Name:	Screenshot_4.png
Views:	536
Size:	22.7 KB
ID:	2106201  
RodneyFord is offline  
Old 06-28-2015, 02:07 PM
  #3  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 421
Gallery
My Gallery
Models
My Models
Ratings
My Feedback
Default

I will go through the process I use to make a composite fuselage. I'm up to about 10 now, the last 2 were 40% IMAC so this one is relatively small.
I dimension the drawing at 100mm stations and transfer it to 6mm MDF. The off cut will be the splitter plate, more on that later.
Attached Thumbnails Click image for larger version

Name:	dimensions.png
Views:	449
Size:	58.6 KB
ID:	2106217   Click image for larger version

Name:	DSC_3076.jpg
Views:	305
Size:	32.7 KB
ID:	2106218   Click image for larger version

Name:	DSC_3077.jpg
Views:	288
Size:	48.1 KB
ID:	2106219   Click image for larger version

Name:	DSC_3078.jpg
Views:	447
Size:	44.9 KB
ID:	2106220  
RodneyFord is offline  
Old 06-28-2015, 02:33 PM
  #4  
ppljr
My Feedback: (94)
 
ppljr's Avatar
 
Join Date: Apr 2002
Location: Grapevine, TX
Posts: 336
Gallery
My Gallery
Models
My Models
Ratings
My Feedback
Default

Nice. Be watching with interest.
ppljr is offline  
Old 06-28-2015, 02:37 PM
  #5  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 421
Gallery
My Gallery
Models
My Models
Ratings
My Feedback
Default

From this point I will use different methods to build the fuselage shape. My first plan was to cut 100mm long cross sections derived from the Solidworks model. However I wasn't entirely happy with the shaping in solidworks so I am going to do the shaping free hand using profile gauges to get symmetry. I did use the CNC foam cutter to do the top view though.

Attached Thumbnails Click image for larger version

Name:	DSC_3079.jpg
Views:	1112
Size:	46.4 KB
ID:	2106221   Click image for larger version

Name:	DSC_3080.jpg
Views:	1110
Size:	40.0 KB
ID:	2106222  
RodneyFord is offline  
Old 06-28-2015, 02:49 PM
  #6  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 421
Gallery
My Gallery
Models
My Models
Ratings
My Feedback
Default

Vacuum bagged the other side on. Am using PU glue as it is fairly fast gap filling and works well in the vacuum bag. I have 2 vacuum pumps. This one is for white foam as is a diaphragm pump and is happy running at reduced pressure (5psi here) so it doesn't collapse the foam. The other pump is an oil filled vane pump for composites in molds and is best run at full vacuum or the oil drains out.
Attached Thumbnails Click image for larger version

Name:	DSC_3081.jpg
Views:	283
Size:	28.3 KB
ID:	2106223   Click image for larger version

Name:	DSC_3083.jpg
Views:	273
Size:	51.0 KB
ID:	2106224  
RodneyFord is offline  
Old 06-28-2015, 03:03 PM
  #7  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 421
Gallery
My Gallery
Models
My Models
Ratings
My Feedback
Default

Trimmed of the outline with a hand held hot wire. Powersupply is a transformer on a light dimmer.
Started roughing out the shape with a bread knife.



Attached Thumbnails Click image for larger version

Name:	DSC_3086.jpg
Views:	293
Size:	56.1 KB
ID:	2106227   Click image for larger version

Name:	DSC_3087.jpg
Views:	374
Size:	40.8 KB
ID:	2106228   Click image for larger version

Name:	IMG_2951.JPG
Views:	1048
Size:	103.0 KB
ID:	2106229  

Last edited by RodneyFord; 06-28-2015 at 03:10 PM.
RodneyFord is offline  
Old 06-28-2015, 03:09 PM
  #8  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 421
Gallery
My Gallery
Models
My Models
Ratings
My Feedback
Default

The canopy/hatch got cut out of the profile and foam glued to it.

Attached Thumbnails Click image for larger version

Name:	DSC_3084.jpg
Views:	1006
Size:	58.3 KB
ID:	2106231  
RodneyFord is offline  
Old 06-28-2015, 03:23 PM
  #9  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 421
Gallery
My Gallery
Models
My Models
Ratings
My Feedback
Default

The fin is built up for accuracy. I use Profilli pro for my airfoil work. The airfoil is SD 8020 with the trailing edge thickened to a blunt 6mm and the root high point moved back to blend into the fuselage. The solidworks model helped to visualise the fit. Once the design was sorted out I printed out the ribs and used a glue stick to attach the printouts to the balsa. Lots of ribs for stiffness. Also made some leading edge templates for accuracy.

Attached Thumbnails Click image for larger version

Name:	DSC_3088.jpg
Views:	1002
Size:	62.4 KB
ID:	2106235   Click image for larger version

Name:	DSC_3089.jpg
Views:	1019
Size:	46.8 KB
ID:	2106236   Click image for larger version

Name:	DSC_3090.jpg
Views:	1031
Size:	57.9 KB
ID:	2106237   Click image for larger version

Name:	fin ribs.png
Views:	1020
Size:	13.4 KB
ID:	2106238  

Last edited by RodneyFord; 06-28-2015 at 10:24 PM.
RodneyFord is offline  
Old 06-28-2015, 03:27 PM
  #10  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 421
Gallery
My Gallery
Models
My Models
Ratings
My Feedback
Default

Did some rough sanding. 40 grit in one hand and vacuum cleaner in the other. Foam can get messy real fast.
Attached Thumbnails Click image for larger version

Name:	DSC_3092.jpg
Views:	426
Size:	49.7 KB
ID:	2106239  
RodneyFord is offline  
Old 06-28-2015, 03:32 PM
  #11  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 421
Gallery
My Gallery
Models
My Models
Ratings
My Feedback
Default

Added the hatch base. This is the zero line to set everything from.
Attached Thumbnails Click image for larger version

Name:	DSC_3093-001.jpg
Views:	215
Size:	48.4 KB
ID:	2106241  
RodneyFord is offline  
Old 06-28-2015, 03:41 PM
  #12  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 421
Gallery
My Gallery
Models
My Models
Ratings
My Feedback
Default

Used the canopy base to set the nose angle at 1/2 degree. There will be no right thrust as the model will have a contra drive or use throttle to rudder mixing if only one prop.
Attached Thumbnails Click image for larger version

Name:	DSC_3094.jpg
Views:	223
Size:	58.3 KB
ID:	2106243  
RodneyFord is offline  
Old 06-28-2015, 04:08 PM
  #13  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 421
Gallery
My Gallery
Models
My Models
Ratings
My Feedback
Default

Glued on the nose ring. Triangulated it for squareness.

Attached Thumbnails Click image for larger version

Name:	IMG_2953.JPG
Views:	1010
Size:	81.0 KB
ID:	2106247  
RodneyFord is offline  
Old 06-28-2015, 04:59 PM
  #14  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 421
Gallery
My Gallery
Models
My Models
Ratings
My Feedback
Default

Gluing the canopy base on.
Attached Thumbnails Click image for larger version

Name:	IMG_2954.JPG
Views:	161
Size:	71.2 KB
ID:	2106262  
RodneyFord is offline  
Old 06-28-2015, 05:45 PM
  #15  
ppljr
My Feedback: (94)
 
ppljr's Avatar
 
Join Date: Apr 2002
Location: Grapevine, TX
Posts: 336
Gallery
My Gallery
Models
My Models
Ratings
My Feedback
Default

What was wrong with the shaping in Solidworks? I have had good success with Rhino 3d.
ppljr is offline  
Old 06-28-2015, 06:18 PM
  #16  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 421
Gallery
My Gallery
Models
My Models
Ratings
My Feedback
Default

Originally Posted by ppljr View Post
What was wrong with the shaping in Solidworks? I have had good success with Rhino 3d.
Solidworks is great. Use it for the 3D printer. For this kind of flowing curve shaping I think Rhino might be better, you know pulling it around with handles. Especially the nose area which is going to be quite complex. I am pretty comfortable with eyeballing it freehand, I think I will get a better result.
Talking about the 3D printer, I will use it to make some parts. I am thinking of inserts to go into the mold for air exhausts. Spat and leg patterns. Am experimenting with nylon filament with a view to doing the 95mm spinner.
RodneyFord is offline  
Old 06-28-2015, 07:15 PM
  #17  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 421
Gallery
My Gallery
Models
My Models
Ratings
My Feedback
Default

Did some rough shaping on the lower nose area. Actually nothing complex here, just want it fairly low drag and smooth here to get the air moving down the fuselage easily. Not worried about taking off too much foam as it is easy to build up later with bondo after it gets glassed. Much harder to take glass away and redo it.

Attached Thumbnails Click image for larger version

Name:	IMG_2955.JPG
Views:	959
Size:	57.2 KB
ID:	2106277   Click image for larger version

Name:	IMG_2956.JPG
Views:	964
Size:	61.8 KB
ID:	2106278   Click image for larger version

Name:	IMG_2957.JPG
Views:	954
Size:	59.9 KB
ID:	2106279  

Last edited by RodneyFord; 07-19-2015 at 01:14 AM.
RodneyFord is offline  
Old 06-28-2015, 09:19 PM
  #18  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 421
Gallery
My Gallery
Models
My Models
Ratings
My Feedback
Default

Double sided tape on some thin card to hold the canopy in place for shaping.
Attached Thumbnails Click image for larger version

Name:	IMG_2958.JPG
Views:	132
Size:	56.7 KB
ID:	2106283   Click image for larger version

Name:	IMG_2959.JPG
Views:	144
Size:	60.7 KB
ID:	2106284   Click image for larger version

Name:	IMG_2960.JPG
Views:	162
Size:	65.5 KB
ID:	2106285  
RodneyFord is offline  
Old 06-29-2015, 04:04 PM
  #19  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 421
Gallery
My Gallery
Models
My Models
Ratings
My Feedback
Default

Got some section lines on so I could see the curves more easily and to check symmetry with the profile gauge.
Attached Thumbnails Click image for larger version

Name:	IMG_2964.JPG
Views:	992
Size:	53.5 KB
ID:	2106419   Click image for larger version

Name:	IMG_2965.JPG
Views:	975
Size:	63.6 KB
ID:	2106420   Click image for larger version

Name:	IMG_2967.JPG
Views:	975
Size:	59.2 KB
ID:	2106421   Click image for larger version

Name:	IMG_2969.JPG
Views:	1009
Size:	66.7 KB
ID:	2106422  
RodneyFord is offline  
Old 06-29-2015, 10:17 PM
  #20  
brustyrc
 
Join Date: Feb 2007
Location: Napier, NEW ZEALAND
Posts: 9
Gallery
My Gallery
Models
My Models
Ratings
My Feedback
Default

Very nice work as usual Rob, I'll follow this with interest, 'best, Barrie.
brustyrc is offline  
Old 06-30-2015, 12:24 PM
  #21  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 421
Gallery
My Gallery
Models
My Models
Ratings
My Feedback
Default

Originally Posted by brustyrc View Post
Very nice work as usual Rob, I'll follow this with interest, 'best, Barrie.
Hi Barrie nice to hear from you.
The interesting bits for me are the things that are done differently or in a new way.
These are:
The free form shaping using the profile gauge for symmetry (I got pretty close by eye)

Polyester mold with gel coat sprayed in with popcorn gun (I got a new compressor that will run continuously)

Engineered mold locating and joining system.

1mm Rohacell for the sandwich material in the finished fuselage.

My first decent size electric model. I might do my own contra gearbox, I mean how hard can it be!
RodneyFord is offline  
Old 06-30-2015, 02:49 PM
  #22  
drac1
My Feedback: (4)
 
drac1's Avatar
 
Join Date: Jul 2008
Location: Romaine, Tasmania, AUSTRALIA
Posts: 1,607
Gallery
My Gallery
Models
My Models
Ratings
My Feedback
Default

Originally Posted by RodneyFord View Post
Hi Barrie nice to hear from you.
The interesting bits for me are the things that are done differently or in a new way.
These are:
The free form shaping using the profile gauge for symmetry (I got pretty close by eye)

Polyester mold with gel coat sprayed in with popcorn gun (I got a new compressor that will run continuously)

Engineered mold locating and joining system.

1mm Rohacell for the sandwich material in the finished fuselage.

My first decent size electric model. I might do my own contra gearbox, I mean how hard can it be!
If it were easy, everyone would be doing it. Lol.

Nah, just kidding. Would be well worth having a go. I haven't seen an exploded view of one, but I think there would be a fair bit of work involved. I'm a first class machinist by trade, so would be very interested. Post plenty of photos and give a good description of what you do if you decide to try.
drac1 is offline  
Old 06-30-2015, 03:57 PM
  #23  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 421
Gallery
My Gallery
Models
My Models
Ratings
My Feedback
Default

Originally Posted by drac1 View Post
If it were easy, everyone would be doing it. Lol.

Nah, just kidding. Would be well worth having a go. I haven't seen an exploded view of one, but I think there would be a fair bit of work involved. I'm a first class machinist by trade, so would be very interested. Post plenty of photos and give a good description of what you do if you decide to try.
The Adverrun looks quite achievable. Need to cut spur gears and make shafts but I am set up for that. The Brenner system is more elegant to my mind but needs a high level of machining.
RodneyFord is offline  
Old 06-30-2015, 03:58 PM
  #24  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 421
Gallery
My Gallery
Models
My Models
Ratings
My Feedback
Default

Took the canopy off and lined the front and rear.
Attached Thumbnails Click image for larger version

Name:	IMG_2970.JPG
Views:	143
Size:	54.8 KB
ID:	2106674  

Last edited by RodneyFord; 06-30-2015 at 06:06 PM.
RodneyFord is offline  
Old 06-30-2015, 03:59 PM
  #25  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 421
Gallery
My Gallery
Models
My Models
Ratings
My Feedback
Default

An issue with this type of pattern is the lack of rigidity. At the moment it is a bit of a banana by 4 or 5 mm. I will need to stiffen it up or anything could happen when I glass it. I have put the laser line on it here to see how it is. I think I will inset some spruce strips along the sides and hold it straight while the glue dries.
Attached Thumbnails Click image for larger version

Name:	IMG_2972.JPG
Views:	122
Size:	48.6 KB
ID:	2106679   Click image for larger version

Name:	IMG_2973.JPG
Views:	126
Size:	48.8 KB
ID:	2106680   Click image for larger version

Name:	IMG_2975.JPG
Views:	145
Size:	62.2 KB
ID:	2106681  

Last edited by RodneyFord; 06-30-2015 at 06:38 PM.
RodneyFord is offline  

Thread Tools
Search this Thread

Contact Us - Archive - Advertising - Cookie Policy - Privacy Statement - Terms of Service

Copyright 2018 MH Sub I, LLC dba Internet Brands. All rights reserved. Use of this site indicates your consent to the Terms of Use.