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Boeing 777-200 LR 1:44 scale (B7 project)

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Old 10-12-2013, 03:19 PM
  #26
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Default 12 / 10 Frame

Today I was producing the frame.
Early concept of inner structure is shown here. It's made of aluminium tube and carbon stripes.

very detailed photoset






This part is an engine support, it will be made of aluminum corner




4 hours and more then 30 cut-off discs later


weight is the same as in the 3D drawing
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Old 10-26-2013, 03:06 AM
  #27
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Default Aluminium

Today I'd like to talk about the mechanization of my aircraft. Here is a small list for a wing:
  1. inboard flap
  2. outboard flap
  3. inboard slat
  4. outboard slat
  5. aileron
  6. spoilers (both)
total of seven moving parts, or, as it's said, ! I'll go in order

First of all, I have chosen a certain plane in the wing with a 7-degree angle to the horizon. This is going to be a layout for all moving parts.


1. Inboard flap


Since I have hollow wings, I decided to implement the construction of the flap by this way


As the bearings I'm going to use brass tubes 3x1.5mm and steel rod with 1.4mm diameter.
Video of the final result
http://vimeo.com/46074754 2. Outboard flap


Outboard flaps are implemented in a similar way

http://vimeo.com/46205474 3. Inboard slat




http://vimeo.com/46258998 4. Outboard slat




http://vimeo.com/46261076 5. Aileron
My basic idea to hide everything inside the wing in this place delivered me the most difficulties. And, if for other elements I am calm, there is still a very large field for r&d.


6. Spoiler
It's simple - no additional mechanisms, one side is fixed, and other will be connected to the servo arm. I saw it somewhere on rcgroups - very simple and easy.


And that's just all in one wing, but there is a tail section


http://vimeo.com/46397445
http://vimeo.com/46460474 and gears


http://vimeo.com/47149996
http://vimeo.com/46473860 All of this was designed, thought out, calculated. Left to do
In fact the entire frame is made so all items could be cut out of the three basic shapes - square tube 20x20x1, 20x20x1 corner and flat aluminum 1 mm thick. I've tried to make a part of frame - I've spent whole day and not satisfied with the results, but the concept is tested and approved


After that, I've realized that I have to place an order for cutting. Calculations gave me the length of cut over 400m And once again I have to find way to make it
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Old 10-26-2013, 06:43 PM
  #28
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Default PETG cutting

I faced with the problem of the plastic correct cutting - I need experienced advice
The basic principle is as follows - moulds were made with the additional 5mm. Then I need some kind of bar with 4mm height with thin blade mounted on the top.


Theory in pictures
Here is the needed detail. Offhand, it consists of two halves - top and bottom.



Moulds will looks like this



Additional forms part for a sacrificial plastic


cutting process will looks something like this
special tool

and a scheme


And here is a reality

Half of the fuselage - why I did a additional step I do not remember, it was 1.5 years ago



I picked up a pack of baby food and make a brick about 4 mm height


I try to cut and here I have difficulty - so I need an advice


In short - everything goes not according to plan
And how would you cut this plastic?



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Old 11-15-2013, 10:12 PM
  #29
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Default Project update


I'll come up for a moment from the world of outsourcing to explain what has been done on the frame.
All frame's parts are conventionally grouped by manufacturing technology and layout angle: +7, +8 and zero.

tube 20x20


already done and is coming to me - the material aluminum 6063.


Laser cutting of flat aluminum

Material - Aluminum 6061-T6, I found the service provider and will get it soon

CNC aluminum machining

used to conjugate planes +7 and zero, already been done and is coming to me - the material aluminum 6063-T5.


carbon fiber strips and rods

five minutes from order

mounting corners

so hard to find supplier, I'm still looking

bearings

Basically found. The outer diameter of 3 mm, 1 mm bore size. Some of them are made ​​of plastic.

styrofoam

Everything I need for cutting tool is bought. I'm waiting the cut templates.

fasteners

M3 and a little bit of M2 is used for frame mounting, so I had to order them


chassis

There still needs to work - here will be used cnc and cutting, rubber and plastic molding, bearing, two kind of springs, M2 fasteners and ...brakes. As always - with blackjack and ...

Who knows, maybe somewhen h-king will sell chassis from SSAir
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Old 11-16-2013, 09:50 AM
  #30
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Amazing!

Thank you for sharing your progress. I will be following you.

Paul
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Old 11-30-2013, 10:18 PM
  #31
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Default 12 / 01 Frame progress

Quote:
Originally Posted by SkidMan View Post
Amazing!
Thank you for sharing your progress. I will be following you.
Paul
Thank you, Sir!

First results of producing frame components.

This is main frame's structures - aluminium tube with cut out holes, weight 198 grams.



This items are used to conjugate inner aircraft planes +7 and zero, weight 34 grams.


Also I got my dsr retracts - dsr 46, frame of my aircraft was especially designed for this system, weight 173 grams.

Seems, my callsign will be "too heavy 777"

Laser cutted details are still to come, I have only process's and quality control's photos


While I was looking for wheels for my chassis I've decided to do it by myself. All wheels with outer diameter about 35mm that are on market or too ugly or too expensive for me. As always I'd like to make my wheels with blackjack and ... - two stamped metal rims, two decorative caps, natural rubber hollow tire, insets for axles with two different diameter, nice M1 fasteners
and all this for ... - yum yum .
Slightly heavy - about 10 grams per assembled wheel (7 grams only for tire), but I'm sure to be satisfied with overall look and quality.


someone wants scaled good-looking wheels?
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Last edited by leadatinbox; 11-30-2013 at 10:26 PM.
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Old 12-14-2013, 05:32 PM
  #32
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Default 15 / 12 Two steps forward - one step back

Two years ago when I was designing airfarme I choosed DSR as retracts for my plane. I hadn’t this at hands while was designing so drawings were taken from their site.
On this week I got my laser cutted items and here is the result.


There are two general types of DSR - 30 and 46. In all of my drawings title 46 participates. but…


It seems that I used 30's drawings instead of 46's, so those parts should be remade.

Wheel 35x13mm
My wheel consists of nine parts.


Today fourth part turn has come. Week ago it looked like this


and today .. ta-da


Next will be M1 fasteners (pos. #5 and #6). They have been bought already and are coming to me.


One more parcel has arrived - micro bearings with outer diameter three mm.

I'm still thinking about main gears axles - may I use 1mm axles with bearings or it won't be enough to carry load?

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Old 12-14-2013, 11:51 PM
  #33
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I've tried to assemble laser cutted parts and realized that instruction has to be done

rough weight is about 160g
+ tubes 170g
+ 4m of carbon fibers strips 280g
and, airframe weight is about 610g
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Old 12-29-2013, 03:26 PM
  #34
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Default 30 / 12 Reverse concept

I'm haunted by edf reverse idea for my CS90
What do you think - is it worth it?




All parts are made of 0.15-0.3mm steel, control rods are 1-1.4mm diameter, fasteners M2, overall weight will be about 50g per engine.

any thoughts?
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Last edited by leadatinbox; 12-29-2013 at 09:59 PM.
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Old 01-01-2014, 02:47 AM
  #35
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Default 01 / 01 New Year update

Happy New Year! I wish you health and prosperity in the New Year!
Let the New Year will be for us full of joyful events and pleasant moments, and failures and non-flying weather bypasses aside!

Tires for my wheel will be made by two stage. First stage is the simplified prototype. And I got it just before New Year


One of it was cut to see the profile


It is slightly heavier than it was planned - about 6.5g / unit


Also I got my m1 fasteners for wheels


By the way, here is another prototype


What do you think about the purpose of this thing?
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Old 01-02-2014, 07:48 PM
  #36
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Default I'm afraid of this thing


ruler is only 46 cm length
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Old 01-18-2014, 11:32 PM
  #37
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Default 01 / 19 The last piece of puzzle

Ok, I'm almost ready to assemble my airframe
Today I'll try to prepare my corners. Couple of months ago I've placed order for it. I need a lot of various corners for my airframe and I can't think of anything better than this method for producing - to lay out all of it on four sides of tube for laser cut. But cutting should left a little bit of space on edges. This will let to make delivery and producing of whole frame more cheap and simple. Chosen method looks like this.


tube isn't very big - 20 x 20 wall thickness 1 mm, length about 60cm


I used this tools but one simple hacksaw is enough for it. At first I freed engine's levers


then everything else


half an hour of work and everything is done


For better look it has to be polished because laser cutting leaves behind small droplets of molten aluminum on the inside surface of the pipe. You may see it on left picture.


After an hour everything is ready for further assembling, corners overall weight is 54g
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Old 01-20-2014, 04:32 AM
  #38
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Default It's Alive!!!

http://www.youtube.com/watch?v=xos2MnVxe-c

B7 frame consists of five groups


flat aluminum details and cnc machined aluminum connectors


specially made wing mechanization items and a little bit of fasteners


aluminium tubes with corners and carbon fiber products


Everything except special M3 fasteners is ready, it's time to make an assembly
At first I've tried to use a stopwatch to determine right time but then I gave up on this idea


Here you can see how my +7 connectors are used


two with a half hours and wing section is assembled


Intermediate weight is 340g (17g is weight of drill bits)


Plus ninety minutes and central part is made also. Its weight 270g


overview


Angles should be +7 on the wing and +8 on the stabilizer


While assembling I've found several details to improve, for example - my logo is made head over heels
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Old 01-27-2014, 04:54 AM
  #39
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Default giveaway

life is such a wonderful thing that you never know where you can find and where you lose

Looks like it's time to finish my B7 project and everything connected to it. In connection with this I announce giveaway of B7 components

shells


and airframe components


all for free, if somebody is interested, please, send me a message
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Old 02-20-2014, 02:30 PM
  #40
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Default Sayonara, B7!

for last three weeks all of ten B7 complects were given in good hands throughout Russia.


I've used 57 square meters of carton and tons of adhesive tape



Overall weight of the goods delivered is more than 200 lbs


Last four were sent yesterday in this big box


For today I can say "Sayonara, B7 1:44"!
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