danfarina44

Hi All,

I will use this thread to show all my progress photos for this project.

I finally got my Fiberglass tube (stabs) in the mail. They're shown in the photo.

I wanted to be able to separate the wing halves for transporting, so I am inserting fiberglass tubes to support the wings.

You can't really see it in the pics, but I reinforced each rib w/ 3/32" ply where the tube is going through the rib.

The tricky part is to keep the dihedral angle accurate and the wings symmetrical. It's tricky, but I think I'm getting it.

First, I'm drilling a 1/4" hole and using a 1/4" steel rod that I already had lying around. If I'm off a little I should still be able to make minor adjustments.

Next I'm going to drill the holes to 1/2" to fit the Black fiberglass tubes. (see photos) You can see that the holes start higher on the right and lower on the left.

None of the ribs a epoxied in yet, so I'll just match each rib left to right to drill hole for the right wing as well.

I'll do more pics when I'm finished with the wings.

If you'd like to add anything, let me know. This was the best method I could think of with what I have available.

Thanks

Dan

Campgems

The one thing I would suggest is to make copies of the four ribs from the main spar to the LE in ply, and use those for the re-enforcements. You want to be able to spread the load to the spar system and if you juse just a hole re-enforcement, your load is going to be carried by the balsa ribs, not the spar system. I got a look at a wing from a 30% Yak the other day and it had full ply ribs as far in as the joiner tube went. One other point, it had a 1 1/2"+ tube. The wing span on that plane is less than the 4*120. Something to keep in mind.

Don

danfarina44

Yikes.

Well....I hope I'm alright the way it is. I def. won't be flying w/ the same forces as 30% Yak, but I see what you mean. I did at least cut them to fit tightly to the main spares Top & bottom, and two smaller 1/4" spares, top & bottom. I'll do a close-up photo to show it later.

If I had my old scroll saw.... I could easily cut ply to match the ribs to the spares. Unfortunately, I'm in a condo...bummer.

I guess I figured since there was no tube there before at all, I wouldn't need more than a 1/2" tube. It's amazing how strong the tubes are, I couldn't break it (by hand) if I tried, especially both tubes together.

I'm CA ing the left wing right now, Right side should go much faster.

Thanks for your help,

Dan

Campgems

Dan, a good subsutite for the scroll saw is a jewelers saw. You can get one for a few bucks, and you can do some really nice work with them. They are limited in throat though so you have to plan ahead on the long stuff. Get one with at least a 4" bow and that should work well. Nice tight knerf also.

If your ply spans the mains and the rear of the two small front spars, you should be OK.

You may be susprised on the load on the wing on that 120. It a big span and a lot of surface. Pulling out of a dive or some of the other "tricks" I've pulled getting into trouble, puts some strain on them. What did you decide to do on tying the halfs together?

By the way, your idea of the steel rod as a pilot has a lot of merit. I'll have to file that one away for future use.

Keep the photos comming.

Don

danfarina44

Hi guys,

I'm very happy w/ how things are developing. I took a few pics of the fiberglass wing stabs. Looks ok so far.. as long as my bottom edges lines up I'll be happy.

I propped up the end of my wing half until the inner edge was perpendicular to the table top, them put a level on the tube. (see pics) Looks really close, should be ok. (a little nervous)


I saw on another 4* thread how to beef up the stiffness off the wing, I'll work on that next.

As far as tying the wing halves together I expoxied some plywood ...uh..plates? to insert T-nuts into. (see photo)

After I get both wing halves built, but not sheeted, I'll put the wing halves together and drill the pilot holes for the T-nuts, and screw in nylon bolts.

I looked up wing tie downs on the net, too $$$. I even have some small ones left over from my P-51 PTS, but they're too small.

I might use an old Tupperware container (flat bottom), And cut some home made ones from that. I can double them up if necessary, the nice thing is I can make them any size I want.

What do you think?

More later...

Dan

vmsguy

Only a nit pick.. But.. You have to be careful using this method. A small error in the "perpendicular" of the center rib could lead to large differences at the wingtip. Consider elevating the wingtip the desired amount instead. This way, you "should" stay consistent.

But other than that.. So far.. Looks good...

danfarina44

Thanks, that's exactly what I did. I elevated the wing tip so my 1st rib would be at 90 degrees. Otherwise in the pic the tube would be sloping up. Thanks again

hrrcflyer

Dan,

One quick and easy way to stiffen up that wing is to add shear webs between the top and bottom spars at least as far out as the wing tube goes. Heck, it wouldn't hurt to add them all the way out to the wing tip. Just my two cents worth.

Keep up the good work!!

danfarina44

Ok, more pics!!.

I'm pleased overall w/ the way the wing halves fit together. : )

They are (seem) even, and slide together nicely w/ the tubes epoxied in place.

I added extra ply pieces between the 1st and 2nd ribs for installing T-nuts for a 1/4" nylon screws to hold the wings together.

My plan right now will be to take an old Tupperware serving tray (clear) and cut a flat piece from it maybe 3" wide and however long 14"..?.

Drill holes to match my T-nut pattern on the bottom of the wings. That should hold the halves together nicely.

I'm also going to reinforce the 1st ribs and use 1 or 2 dowel rod stubs to line-up the trailing edges.

Let me know what you guys think.

Thanks ,

Dan

danfarina44

Ok, I feel like my progress is slow lately, but at least I've made progress.

I took a few pics (good and bad). I think my turtle deck came out so so, I guess I'll just fill in the bad spots with wood filler. Any body else ever done s/thing like this , this badly?

It was harder than I thought to cut the pieces to fit. Can I borrow some wood filler anyone?

After I sanded it it looked 1000X better. Still need to hand sand.

I also didn't clamp down the edge of my sheeting on the wing. GGGGRRRRR!!

I added ply w/ T-nuts to tie the wing halves together, and a balsa block to beef up the leading edge for the dowel.

Any comments or suggestions are welcome.

Thanks guys,

Dan

danfarina44

Hi All,

A few more pics. So far so good. In a hurry right now. Helpful comments appreciated.

Dan

hrrcflyer

Dan,

Have you ever tried Evercoat filler. You can but it at places that sell automotive paint and supplies. If you want to try it, make sure you get the container with the teal label and not the blue label. The hardener comes in a separate (much smaller) tube. A long time flying friend turned me onto the stuff and it works GREAT. It's easy to sand and is lighter than wood filler. Be advised, don't use very much of the hardener or the stuff will dry before you get the chance to get it mixed... Don't ask me how I know.

Happy Holidays

flygilmore

As far as the turtle deck, there are different ways to fill in with balsa. One way that might have worked better for you is to have used balsa planks: for ex. 3/32 x 1" x 36" and sheet that way. After all have been placed, sand and it looks like one smooth sheet. Many cowls are made this way. Of course, don't use CA for this as it will leave hard edges and not sand very nice.

danfarina44

Hi Guys,

Some new pics.

I finally made time to install all the hinges. You can see that I sheeted about 80% of the wings. I don't think it added too much weight. We'll see.

I'm not quite done w/ the wing tips, still too big.

I weighed it on my bathroom scale, not sure how accurate it is, right now the plane and motor weighs about 8 lbs. (plane and motor) Completed it supposed to weigh 12 to 13 lbs. So I guess I'm on track...?

Next steps: mount the motor, install the on board equip., balance for CG, final sanding and fit, and of course ...covering.

Any helpful hints appreciated.

Thanks,

Dan

P.S.: The red "stick" is a 12" ruler! This thing is a monster!

beachflier

Dan,

I am assuming you have not yet glued in you hinges. You may want to adjust the slots to close the gap.

Also what engine are you going to be using?

danfarina44

Right thanks,

I'm using the 26cc engine from BCMA. w/ the wrap around muffler. I also bought a Cap 21 cowl and wheel pants from Fiberglass Specialties. I hope it'll have enough power.

I've also made pontoons for this plane as well. Here's a video on You Tube.

http://www.youtube.com/watch?v=3JpgePMLAI4

No, I have not glued the hinges yet. I was wondering if my gaps were too big, I will def. fix that.

I'll do the Aerocoat first, then glue the hinges. I've already cracked the wood on 1[], pressing too hard. I fixed it w/ epoxy.

Some of my sheeting is too thin also in a few spots. I think i'm just going to remove the weak spots. Once I cover the whole thing i think it will cover the small mistakes anyway. Won't it?

I've pressed the Aerocoat down tight against any spots I think might show any faults, so far I can't see any bumps or problems.

The wings are really strong also. With the extra cross bracing I added, the extra sheeting and the Aerocoat I think I'm in good shape. Can they be too stiff?[sm=72_72.gif]

I'm more concerned w/ how the ailerons and my wing tips line up. Also how well the wing fits into the fuse, and of course the Covering. So far I haven't had any major problems.

Taking my time though, it's cold here anyway.[:@]

Thanks again for the tip,

Dan

danfarina44

Just a couple of pics, getting there! Tell me what you think.

danfarina44

Hi Guys,

Ok I'm almost done!!!!!!!!!!!!!!!

Just got her running today! Been breaking in the engine off & on today.

Here's my latest videos. The one on VIMEO is more recent and has a little more footage.



http://www.youtube.com/watch?v=wwvEEgOmbkc

http://www.vimeo.com/737785

Thanks for watching

Dan