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Eagle Aviation One Design Build

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Old 10-23-2011, 08:33 AM
  #1
Tony Hallo
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Default Eagle Aviation One Design Build

Winter coming to western Pa and that means it's building time. A friend of mine bought an Eagle Aviation One Design that had the plans so this is subject for my next build. I plan to finish the plane as the attached full scale. Looks like the same colors as Aeroworks 50cc Edge.
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Old 10-23-2011, 08:41 AM
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Commercial cowl is not available so I must dupicate the cowl from my friends plane. This worked out well since the original cowl was already cut and my friend plans to change engines. So I need to make 2. I found the work below very interesting and decided to try this method using Ultracal 30 from US Gypsun.
I filled in the cutouts in the original cowl and use it for the plug.
www.youtube.com/user/sevarg7226#p/u/44/DkrRybDx5Y4
The results provided acceptable results at considerable time saving verses laying up a epoxy mold. Not perfect but compleetly accepable.

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Old 10-25-2011, 03:49 PM
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Default RE: Eagle Aviation One Design Build

The original design used1/4" balsa for the engine box/wing tube//landing gear box. This was surrounded by 3/8" square balsa. I substituted 1/4" lightply for sides and provided lightening holes. The original floor was 1/4" lightply, I used 1/8" lightply except under the gear where 1/8" aircraft ply was used. I cut the pieces to interlock much like a currentARF, this takes the bows out of the lightply.
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Old 10-26-2011, 06:47 AM
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Default RE: Eagle Aviation One Design Build

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Old 10-31-2011, 01:35 PM
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Default RE: Eagle Aviation One Design Build

I had the day off work so I put ina shift in the man cave. The cowl will be mountedon 4 aluminum pins, the pins will be cross drilled and tapped for 4-40 screws. Slide to cowl on the pins and install the screws, no fiddling around lining up screw holes. I left a small flange on the back of the pins so if the glue joint fails the pin will not pull out. I also added grooves to increase the holding power.
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Old 10-31-2011, 01:44 PM
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Default RE: Eagle Aviation One Design Build

I dry fit everything together and held everything thing in place with servo screws.
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Old 10-31-2011, 01:48 PM
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Default RE: Eagle Aviation One Design Build

I bought 4'x8'x1/8" sheet oflite ply from the local lumber supply company. The sides are 56" long so this avoids a splice.I use a 3/4" hole saw to put the radius in the corners and cut the straight lines with a utiliyknife. The sides are flat to the front of the lightening hole, from that point forward they bend to fit the shape the the cowl. We'll see how that Itialan bending plywood works. I expect to have some problems there.
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Old 10-31-2011, 09:21 PM
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Default RE: Eagle Aviation One Design Build

looking good.... i like the way the front end and cowl looks... i remember seeing one fly with a gemini 160 about 10 or 12 years ago, it looked like the one i saw on the cover of an old RMC mag in the 90s
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Old 11-09-2011, 01:17 PM
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Default RE: Eagle Aviation One Design Build

The liteply sides bend better had expected. I saturated the wood with ammonia and water mixture and after 2 hours I was able to clamp and screw the sides into position.
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Old 11-09-2011, 01:20 PM
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Default RE: Eagle Aviation One Design Build

The liteply pulled in nice around the two front formers. I let this dry overnight and glued everything together today. The wood is still a little damp where the clamping angles were located.
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Old 11-20-2011, 09:51 AM
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Default RE: Eagle Aviation One Design Build

I used the "stand the plane on the tail" trick to align the engine. I'm using a D&B 5.1 for power. I cut the engine box about 1/2" short to allow for better cooling on the right cylinder. I will either shim with a plywood ring or use aluminum spacers that were provided in an Aeroworks ARF that I recently assembled for a friend. That was my compensation!
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Old 11-26-2011, 04:27 AM
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Default RE: Eagle Aviation One Design Build

I use servo screws for trail fitting and gluing, the screws are removed and 1/8" bamboo pins installed once the epoxy has cured. On to the tail plane. Need to order landing gear from T-N-T.
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Old 11-26-2011, 09:20 AM
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Default RE: Eagle Aviation One Design Build

Tony, love the plane and your work! thanks for posting. i sure am learning by very picture. don
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Old 11-26-2011, 10:26 AM
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Default RE: Eagle Aviation One Design Build

Thanks, I hate to type, pictures say more.
The tailplane is built up from3/8" thick stock, I make the hinges act as a pins for those connections, the remaining joints are pinned with 1/8" bamboo scures. This is probally overkill but I'm sure the joints will say put. There's a lot of vibration even with twins.
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Old 11-26-2011, 10:31 AM
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I made two sanding jigs for radiusing the edges, I drilled a 7/16" hole through a piece of maple boom stick then split in two halves, one for 150 grit, the other for 220. It's about 6" long. I knock the edges off with a Master Airscrew plane then finish the rest with 150 then 220. I color the edge surface with the side of a pencil then sand until the pencil makings disappear.
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Old 11-27-2011, 04:13 PM
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The tail plane will be removable. Two 4-40 screws will hold the stab in place, I like to counterbore the dowels so that the socketheads don't sick up. I used a Dremel tool with an end cutter to mill the slot for the 3/4"x1/8" plywood that will hold the stab in place.
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Old 11-27-2011, 04:17 PM
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The finished slot, I mask off the area around the slot to keep the epoxy from making a mess. I mixed 6 grams of West System (The smallest amount I can measure) and blended with microfibers to thicken. The plywood tab is installed using plastic rap to prevent gluing the stab on..
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Old 11-27-2011, 04:28 PM
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Default RE: Eagle Aviation One Design Build

The stab is clamped into position while the epoxy cures. The epoxy that sqeezed out is wiped clean while it's still uncured. The tail isoff .07 degrees or an error of .0015"/inch, that's close enough for me.
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Old 12-10-2011, 05:02 PM
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Default RE: Eagle Aviation One Design Build

Nice build!! I have one of these eagle aviation 38% one designs! I had a pair of two built the same from a reputable builder. The first one is no longer with me[&:]Has a zdz 80 twin.. Most of the ply was replaced in the plane with aerospace honeycomb and carbon fiber.. It is a beautiful plane and built top notch.I need to make space as I have a line of arfs coming in!!! Its a nice plane and needs a good home as I have other ventures..Includes a zdz 80 b2 twin (needs new prop bolts as the old ones broke in the hub), painted carbon spinner, and hitec digital servo's..1000.00 picked up buys it!!
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Old 12-10-2011, 06:09 PM
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Default RE: Eagle Aviation One Design Build

Tony, you will love the D&B. I had one about 10 years ago and it was a ral sweet running engine. The only thing I would suggest doing is replacing the plug wires. I had radio issues until I canged mine. I called DA and they had a fried 3W ignition that they clipped the wires and caps off of and sent to me. The current wires just plug into the backplate mounted ignition. To install the new ones just plug them in like the old ones and secure them with a little Shoo Goo or Goop adhisive. You will need to solder a wire to the sheilding with an electrical terminal on the other end and ground it to the engine case via a mounting bolt.
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Old 12-12-2011, 05:38 PM
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Default RE: Eagle Aviation One Design Build

The landing gear has arrived from T-N-T. I decided to use the J&J tailwheel for this build, the wire is 1/4" titanium, CNC'd aluminum bracket with a 1 1/4" Dubro wheel, nice but pricey at $75.00. Weights 3.2 ounces. The plastic mounting pieces were too wide to use on this fuselage so I went the old fashion route, plywood with a groove. Most fuselages today are wider at the rudder post since airfoil shaped surfaces are uilized. This old clunker has built up flat surfaces.
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Old 12-12-2011, 05:46 PM
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Default RE: Eagle Aviation One Design Build

Nothing high tec for main gear, 6061T6. I use #8 sheet metal screws for securing, no machine screws and nuts here, much easier than fighting with bolts and nuts. I discovered this method from a Bob Godfrey One Design, works great.
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Old 12-22-2011, 05:17 PM
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Default RE: Eagle Aviation One Design Build

Let the wing construction begin. The wings will be foam rib construction. About 20 years ago I made this jig to build a Urley 33% Laser. The ends have sagged over the years so before beginning I added 2'X4'x5/8" particle board to the top. This really increased the weight but it is flat now. The jigs are made to bolt together to allow the wing tube to be cut at the same time in both panels. The wing tube centerline is layed out from tip to tip. Parting stock is use to retain the foam blanks in place per plan spacing. The strips are held in place with braids.
I normally use 1/2" thick blue foam with 5" rib spacing, the plans show slightly less than 4" spacing so I plan to reduce the 1/2" foam to 3/8" to keep similar weight construction.
List of planes build using this jig;
33% Urley Laser
33% Extra 230 (Modified ACE design)
33% Godfrey Extra 300
33% Extra 200 (Tony Design)
35% Hurley Extra 300 LX
38% Godfrey One Design
38% Eagle Avaition One Design
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Old 12-23-2011, 01:40 PM
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Default RE: Eagle Aviation One Design Build

I will be using a 1 1/2" carbon fiber tube for the wing. I like to make my own sockets because they fit the tube better. I must say the tube for this plane that was purchased from T-N-T Landing Gear measures very close to 1.500". On my last build the tube measured 1.490".

To start I coat the tube with Vasoline, poor man's release agent. Next a piece of wax paper cut slightly longer than the perimeter is wrapped around the tube. The wax paper is wound around the pressed into the Vasoline as I go. Once it makes contact the paper becomes black the color of the tube. Just work slowly rubbing until contact is achieved.
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Old 12-23-2011, 01:46 PM
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Default RE: Eagle Aviation One Design Build

Next 6 ounce cloth is cut on a 45 degree bias. In this case I cut the cloth long enough to wrap around the tube twice. I need about 14" per side so I'm making the sockets 18" long and will trim to fit. The cloth is wetted on a piece of wax paper and rolled onto the tube. Again working slowly so that all the air bubbles are worked out. I'm using West Systems with slow hardener so there's plenetly of time.
I purchased a sheet of extruded polystryene today at Lowes, it is green in color. I hope it cuts as well as the Owens pink nad Dow blue color sheets did. The protective plastic covering came off much easier the pink or blue material did. Will know how it workssoon. First up cut the thickness down to 3/8".
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