SunDevilPilot

Cross-brace is installed...

The blocks are mounted to the fuselage sides, the lower former, and to each other. This should be plenty strong to make the cables functional.

In looking at the angles, along with the perceived direction of flight induced forces, I believe the cross-brace will transfer the load nicely into the fuselage and into the opposing wing.

SunDevilPilot

knucklebutt

Will "Inserts" be strong enough for the pull on flying wires ? I usually use "Blind Nuts"

I guess we will find out huh ???

SunDevilPilot

I think so... They are epoxied into the block so they should never come out.

The outer portion of the insert has threads with cross cuts splitting the threads. These should be full of epoxy. I wet the hole with epoxy, wet the insert, and screwed it in.

SunDevilPilot

SunDevilPilot

Here is what I came up with for the rear flying wire mounting point. Like the front, the rear are made from maple blocks with some brass inserts. I did make a removable cross brace to protect the bottom of the fuselage. There is not a lot of structure in the area of the lower wing saddle so I wanted a brace in place to prevent the sides from being pulled out by the tension in the wires. By making it removable I will still be able to get into the fuselage to install the radio gear.

There is also a piece of plywood running vertical to spread the load up towards the top of the fuselage. Again, preventing the tension in the wires from crushing the fuselage.

The wires are not part of the kit in its stock form so I had to be a little creative to add them. I think it will be worth the effort.

Adding the hard-points for the flying wires would have been an extreme challenge if I would have waited until after the fuselage was sheeted.

SunDevilPilot

WacoNut

Looks good SDP,
May I suggest adding diagonal braces to that piece attach them to the top fuse former. It could mount to the same bolts you installed. I am afraid any side force you may see from a ground loop or such may give you some issues. The diagonal braces would help in this respect.
Later!!
Anthony

SunDevilPilot

Thats a really good idea. I'll look into that when I get to installing the radio gear. Maybe I can incorporate some diagonal bracing into the radio tray that connects with the cross-brace I just made.

SunDevilPilot

WacoNut

You will be amazed at how much tugging functional wires will do to an airframe.
Later!!
Anthony

radfordc

My Feedback: (14)

Very clever... and more than strong enough. I didn't use a cross member and no issues so far.

I did wait until after sheeting the fuse to do my flying wires. Here is are pics of how I did it. I used aluminum tangs screwed into the front landing gear block and to the fuse sides.

SunDevilPilot

Thanks for the photos Radford.. That looks like a good method too. The front was easy in comparison to the rear. The gear mount on your plane made for a great hard-point.

It is amazing how fast the fuselage fills up. The method of building a crutch then the outer stringers certainly reduces the available space.

SunDevilPilot

SunDevilPilot

In preparation of sheeting the fuselage I needed to make a stand to hold the fuse. The best thing I could come up with was a rounded cradle.

So, this morning I took advantage of some cooler weather outside and whipped up the stand. Was made from some left-over maple I had around. It will get some foam (Pipe Insulation) in the cradle area. The radius of the cradle will match the fuselage when the foam is added.

Only took about 45 minutes to make, was fun. Due to the heat in the garage I haven't had a chance to play with some of my larger woodworking tools in a while.

SunDevilPilot

radfordc

My Feedback: (14)

Wow, even your cradle is a work of art! I made a similar cradle but with two supports tied together with cross members.

SunDevilPilot

That looks like my Thunderbolt fuselage stand.

For this plane the stand is really only needed during construction. Once built the plane will sit on it's landing gear. That is why I made it for the front of the fuselage only. The back can just sit on the table during the building process.

The Thunderbolt is transported and assembled on the stand.

This plane will likely need a wing carrier built too. Here is one I did for my last project, a 1/4 Super Cub.

Some of the guys make fun of me at the field for having "fine furniture" stands and carriers that rival the construction of their dinning room furniture. I enjoy all types of woodworking so I don't mind putting in the "effort" to make a nice stand. I always try something new such as finish type, joinery, etc with each project. This helps me learn and if it gets messed up it is no big deal.

SunDevilPilot

SunDevilPilot

Stand complete.

SunDevilPilot

AmishWarlord

My Feedback: (5)

Looks good SDP but that ugly foam has got to go.

If we lived closer I'd teach you how to make a padded leather wrap for that cradle.

SunDevilPilot

After sanding the stringers / formers of the forward fuselage I began adding the 1/32 ply sheeting.

The center top sheeting is designed to be a one piece job. However, the design of this portion of the fuselage has a compound curve in it so I decided to make it two pieces, a front and rear. I have seen other planes with this same modification. My plan for the top center sheeting is to work down the fuselage alternating sides. Once the forward piece is done I will work on the rear sheeting surrounding the cockpit.

I hope this goes well!

SunDevilPilot

SunDevilPilot

Stringer two.... The stand I made is working good.. It allows the fuselage to sit at any angle which is making the sheeting process a lot easier.

Due to the round shape it is really an issue to find good clamping locations. I went with tape on the front edge of the sanding bar.

SunDevilPilot

SunDevilPilot

Forward Center Sheeting complete.

I used a piece of brass tubing with one end sharpened to open up the cabane mounting points on each side of the fuselage through the sheeting. The tubing made a nice sharp cut.

Next up, the cockpit center sheeting.

SunDevilPilot

SunDevilPilot

The cockpit was marked out on the sheeting, cut with the scroll saw, and fine tuned with my spindle sander. Then the sheeting was installed around the cockpit. I am glad I did the center sheeting as two pieces, made the process easy.

I also removed the center spars from the area of the cockpit.

Now it is starting to look like a fuselage.

SunDevilPilot

VincentJ

Looks great SDP!

gluepicker

Thank you for a an excellent build thread SDP. I've been eyeballing this kit for a couple yrs. now and will start one this coming building season. Know what you mean about that low angle block plane! Haven't found a power tool yet to replace it in the woodshop.

SunDevilPilot

It has been a fun build GluePicker! There are some parts that are a little challenging but with some patients it is coming together nicely.

This weekend was spent making some repairs to my other planes. My 29% Edge had a deadstick several months ago due to a stiff clunk line and landed (AKA Crashed) in the desert surrounding out field. Damage was minor but I put it in the corner and was less than motivated to fix it. All repaired with exception of the landing gear, which needs replacement. I also had to fix my Thunderbolt which last weekend made a belly landing due to one of the gear getting stuck in the well. Damage was minor, scratched belly pan, scratched wingtip, and damaged prop. That one is all repaired.......

However, I did get a chance just now to install the sheeting into the lower wing saddle.

After the glue dries I will fill in the gaps and trim the sheeting. The manual instructs you to leave the sheeting long and match the plywood side sheeting to the wing saddle. I am going to change this up, as others before me have done, and trim the wing saddle sheeting flush with the sides of the fuselage and just sheet over them. After the side sheeting is on I can just trim it to match the saddle.

The book said to just glue the sheeting in. I, however, am using the wing as a weight to ensure the saddle is a perfect match to the curve of the wings.

SunDevilPilot

SunDevilPilot

Wing saddle sanded flush with fuselage formers. Now I am ready for the side ply sheeting..... I'm stressing a little over that process. Time will tell if my fear is unfounded.

SunDevilPilot

SunDevilPilot

The right side sheeting is installed on the fuselage and once the glue dries I will "unwrap it". Right now there is so much tape and clamps on the fuselage it doesnt even resemble a plane.

To install the sheeting I first drilled the holes for the flying wires. Then I put a couple bolts into the hardpoints to reference the sheeting. The edges were marked out, rough trimmed with the bandsaw, and fine tuned with a sanding bar.

I'll post a photo in a while of the before and after.

SunDevilPilot

SunDevilPilot

The sheeting still needs to be trued and sanded at the seams but here is where I am at.

I'm happy with the results.

SunDevilPilot

gluepicker

More great tips SDP. Have appreciated those from fellow subscribers too. I've never built a BUSA kit before and all these tips and links are very helpful. Have you seen the concurrent "28" build on modelflyimg.com uk by British modeler Tim Hooper? He has some neat pix of his intended EP setup. The SR Battery Backer system looks interesting.