Sun Ray biplane
06-26-2010, 10:48 PM
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RE: Sun Ray biplane
I made the 1/2" Balsa nose block and 1/16 ply ring.
Drilled firewall for engine mount, throttle push-rod and fuel lines.
Installed 6-32 blind nuts in firewall for Dave Brown # 5060 engine mount.
Marked former locations on inside of fuselage sides and drew center lines on formers.
Next step is to assemble fuselage!
Drilled firewall for engine mount, throttle push-rod and fuel lines.
Installed 6-32 blind nuts in firewall for Dave Brown # 5060 engine mount.
Marked former locations on inside of fuselage sides and drew center lines on formers.
Next step is to assemble fuselage!
06-27-2010, 01:01 AM
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RE: Sun Ray biplane
I just noticed the ply fuselage doublers should end just passed the firewall. Oops, I made a mistake! I made them extend all the way to the front. It shouldn't be a problem though, other than being harder to sand when rounding the nose.
I also relocated one of the fuel line holes in the firewall. It was too near the corner, where the triangle stock will go. I think my building skills are a little rusty!
I also relocated one of the fuel line holes in the firewall. It was too near the corner, where the triangle stock will go. I think my building skills are a little rusty!
06-28-2010, 01:14 AM
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RE: Sun Ray biplane
I joined the fuselage sides. First I epoxied bulkhead # 2 and let it dry. Then I installed the rear 1/4" sq. balsa cross bracing, bulkhead # 3 and joined the fuselage rear. Next I installed the cross brace by the lower wing sadle and added a few temporary 1/4" sq. cross braces to help keep everything square. Then I installed the firewall and nose block.
06-30-2010, 10:12 PM
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RE: Sun Ray biplane
Getting her done little by little. It sure feels good to be building again. It's been a while.
Installed balsa triangle stock in the engine compartment and fuel tank area.
Sheeted fuselage bottom.
Installed 1/4" balsa stab plate and 1/8 sq. balsa for the turtle deck.
Installed turtle deck formers and stringers.
Stab and fin just mocked up. They haven't been glued yet.
Installed balsa triangle stock in the engine compartment and fuel tank area.
Sheeted fuselage bottom.
Installed 1/4" balsa stab plate and 1/8 sq. balsa for the turtle deck.
Installed turtle deck formers and stringers.
Stab and fin just mocked up. They haven't been glued yet.
07-01-2010, 01:41 AM
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RE: Sun Ray biplane
ORIGINAL: resin
Mike,
How do you plan to handle your canopy needs?
Mike,
How do you plan to handle your canopy needs?
07-01-2010, 02:06 AM
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RE: Sun Ray biplane
I planked the turtle deck with 2 pieces of 1/16" balsa. I first glued them to the top stringer and then carefully warped them over the framework while dampening them with hot water. I trimmed them with a straight edge before gluing the sides down with CA.
07-03-2010, 12:33 AM
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RE: Sun Ray biplane
Okay......coated engine compartment and fuel tank compartment with finishing resin
Installed 1/4" ply upper wing plate, braced with triangle stock for extra strength
cut 3/4" balsa triangle stock down to 3/8" high for the fuselage top
added 3/8" and 1/4" balsa top blocks and roughly rounded to shape
I'm waiting for my CB 2 3/4" spinner to arrive before I finish rounding the nose.
I must reference the instructions more often! I should have waited to glue the 1/4" ply upper wing plate until the wing is placed in the saddle. I'll undoubtedly need to cut it back out and realign with the wing in place.
Time to build some wings!
Mike
Installed 1/4" ply upper wing plate, braced with triangle stock for extra strength
cut 3/4" balsa triangle stock down to 3/8" high for the fuselage top
added 3/8" and 1/4" balsa top blocks and roughly rounded to shape
I'm waiting for my CB 2 3/4" spinner to arrive before I finish rounding the nose.
I must reference the instructions more often! I should have waited to glue the 1/4" ply upper wing plate until the wing is placed in the saddle. I'll undoubtedly need to cut it back out and realign with the wing in place.
Time to build some wings!
Mike
07-03-2010, 03:29 AM
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RE: Sun Ray biplane
ORIGINAL: resin
I like your sanding tool. Was that your Dad's?
Keith
I like your sanding tool. Was that your Dad's?
Keith
No, it's actually not very old. It's an auto body sander. I think the sand paper is 50 grit and will rip thru balsa like butter.
Mike
07-03-2010, 07:05 PM
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RE: Sun Ray biplane
ORIGINAL: AllTheGoodNamesAreTaken
Cool plane! Looks like a fun build. Save those rib templates, I may want to borrow them...
Cool plane! Looks like a fun build. Save those rib templates, I may want to borrow them...
Sorry I missed replying to your post. I was distracted with obtaining the construction article.
The Sun Ray has been a very fun build so far. Hopefully the wings go together quickly so I can begin finishing this very cool biplane. Guess I will paint the fuselage and cover the wings with Monokote as recommended in the instructions.
Just let me know when you're ready for the templates. I'll let you borrow the plans too.
Mike
07-05-2010, 03:01 PM
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RE: Sun Ray biplane
I notched/slotted the upper wing spars, leading edges and trailing edges. My little Dremel scroll saw worked perfect for making the notches.
You can use a piece of 1/4" triangle stock to hold the 1/4" square leading edge at the correct angle for cutting the notches.
The mocked up wing panel is holding itself together without glue. I can actually pick it up without falling apart. Neat!
You can use a piece of 1/4" triangle stock to hold the 1/4" square leading edge at the correct angle for cutting the notches.
The mocked up wing panel is holding itself together without glue. I can actually pick it up without falling apart. Neat!
07-07-2010, 12:23 PM
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RE: Sun Ray biplane
I also the sunray 1974 ventage and knew jack scarobough back in 73 and saw the orignal plane fly the plane i have was the 2nd kit they sold
took mine out of mothballs6 month ago rebuilt wings and recoverer
extend tne ply doubler all the way to tail plans show 3/4 of the way also use spruce for wing spars plans show balsa
took mine out of mothballs6 month ago rebuilt wings and recoverer
extend tne ply doubler all the way to tail plans show 3/4 of the way also use spruce for wing spars plans show balsa
07-07-2010, 05:52 PM
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RE: Sun Ray biplane
ORIGINAL: sunraywest
I also the sunray 1974 ventage and knew jack scarobough back in 73 and saw the orignal plane fly the plane i have was the 2nd kit they sold
took mine out of mothballs 6 month ago rebuilt wings and recoverer
extend tne ply doubler all the way to tail plans show 3/4 of the way also use spruce for wing spars plans show balsa
I also the sunray 1974 ventage and knew jack scarobough back in 73 and saw the orignal plane fly the plane i have was the 2nd kit they sold
took mine out of mothballs 6 month ago rebuilt wings and recoverer
extend tne ply doubler all the way to tail plans show 3/4 of the way also use spruce for wing spars plans show balsa
Your Sun Ray is totally awesome! I love the paint scheme and thanks for the building tips. The full length fuse doublers sounds like a good idea. Unfortunately I already assembled my fuse. Maybe I will remove some of the lower cross sheeting so I can install some rear doublers to strengthen the stabilizer area. It feels pretty solid as is but some extra strength in that area couldn't hurt.
Spruce wing spars would add tremendous strength to the upper wing. I actually thought about using spruce spars but went with balsa as shown on the plan. I did add 1/16 balsa vertical grain sheer webs to the back side of the spars which adds a lot of strength. I also made the ply dowel plates extend from rib to rib for extra strength. Maybe I should install sheer webs on both sides of the spars. That would be extra strong.
Very interesting you knew Jack Scarbrough and very interesting a Sun Ray kit was once available! I didn't know a kit was ever available. I'd love to find one! I'd especially like to find plans for Jack's Delta Pusher. It was briefly described in the April 1978 RCM Sunday Flyer column. That column has the only picture or info I've ever found on this very cool looking model. Here is the picture from the column and a couple new construction photos.
Mike
07-07-2010, 11:45 PM
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RE: Sun Ray biplane
Mike,
If you want to add additional strength in AFT fuse area, you might what to consider opening the bottom of your fuse, and place a few light plies of fiberglass with light weight fiberglass resin.
Keith
If you want to add additional strength in AFT fuse area, you might what to consider opening the bottom of your fuse, and place a few light plies of fiberglass with light weight fiberglass resin.
Keith
07-08-2010, 10:22 PM
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RE: Sun Ray biplane
ORIGINAL: resin
Mike,
If you want to add additional strength in AFT fuse area, you might what to consider opening the bottom of your fuse, and place a few light plies of fiberglass with light weight fiberglass resin.
Keith
Mike,
If you want to add additional strength in AFT fuse area, you might what to consider opening the bottom of your fuse, and place a few light plies of fiberglass with light weight fiberglass resin.
Keith
07-08-2010, 10:40 PM
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RE: Sun Ray biplane
ORIGINAL: sunraywest
do you have any spec on the delta that might be in the column
do you have any spec on the delta that might be in the column
Wingspan 54"
Area 700 sq. in.
Length 63 1/2", (43 3/8" disassembled)
Weight 7 3/4 lb. includes 8 oz. nose weight
Wing section root 64A014, Tip 64A215
Engine: 60
"Elevator, rudder, and aileron servos mounted in center wing. Motor servo in fuselage. Nose wheel operates off extra servo mounted in fuselage, runs on splitter wire from receiver rudder outlet. This allows easy wing attachment to fuselage at the field."
07-13-2010, 02:37 AM
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RE: Sun Ray biplane
Upper wing panels finished except for final sanding. I glued sheer webs on both sides of the spars for extra strength.
I'd be almost finished if this was a monoplane but I still have another wing to build!
I'd be almost finished if this was a monoplane but I still have another wing to build!
07-15-2010, 06:54 PM
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RE: Sun Ray biplane
Subscribed: I love planes that are out of the ordinary and not ever going to be arfed. Cant wait to see the finished product. I have never done a plan built airplane, but have done more kits then i can remember. Finishing up a CG Super chipmunk, then I gotta build a BT flying king for my kids. Then im gonna have to build a sun ray. Cool airplane.
07-16-2010, 10:45 AM
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RE: Sun Ray biplane
ORIGINAL: dragonov3
Subscribed: I love planes that are out of the ordinary and not ever going to be arfed. Cant wait to see the finished product. I have never done a plan built airplane, but have done more kits then i can remember. Finishing up a CG Super chipmunk, then I gotta build a BT flying king for my kids. Then im gonna have to build a sun ray. Cool airplane.
Subscribed: I love planes that are out of the ordinary and not ever going to be arfed. Cant wait to see the finished product. I have never done a plan built airplane, but have done more kits then i can remember. Finishing up a CG Super chipmunk, then I gotta build a BT flying king for my kids. Then im gonna have to build a sun ray. Cool airplane.
Good to hear some more interest in the Sun Ray! It's certainly a unique design that will draw attention at the flying field. No doubt the lower gull wing is what makes us look twice. One of my favorite airplanes of all time is the Corsair. I remember watching the television series Ba Ba Black Sheep when I was a teenager just to see the Corsairs!
07-16-2010, 01:52 PM
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RE: Sun Ray biplane
ORIGINAL: sunraywest
looks like the picture is a negative image
looks like the picture is a negative image