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RE: Bell Hop Scratch Build - 1/4/2013 3:52 PM   
sensei



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quote:

ORIGINAL: Joystick TX

Good input.

I have a few other challenges that are unique. None of the internal structure will be the same.

My plan is to keep the basic outline and moment arms the same.

The main fuselage structure, the tail surfaces, and some of the wing will be built from expanded PVC foam, AKA  ''Klegecell.'' It requires a lot of thought and planning to get it to work on aircraft. It has no grain and is not very rigid. It is also heavier than balsa or lite ply. This is my second ''big'' aircraft that will use it. The wing loading will be about one-third heavier than the kits of this size.

I completed the lofting of the fuselage side and top and have marked the firewall and bulkhead locations using the TLAR method. 

The Klegecell fuselage sides will be skinned with 1/16'' balsa. Now I need to determine if I need to bother with lightning holes at this point to meet my design weight goal of 15 lbs.

For those of you who never saw this plane, here is the picture from the magazine:


I am just curious, what is the deciding factor to use the Klegecell over a lighter building material?

Bob

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RE: Bell Hop Scratch Build - 1/4/2013 4:22 PM   
Joystick TX



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quote:

ORIGINAL: sensei

I am just curious, what is the deciding factor to use the Klegecell over a lighter building material?

Bob


It is cheap and easy to work with, it is also fuel resistant. I started using it many years ago when the price of balsa went out of sight and was hard to get. I could get a 4' x 8' x 1/4" sheet of Klegecell for $20.

The weight does not seem to be a big issue, so far, my wing weighs 1lb-12oz, without the aluminim wing tube.

< Message edited by Joystick TX -- 1/4/2013 5:36 PM >


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RE: Bell Hop Scratch Build - 1/4/2013 8:17 PM   
balsa brain


 

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Status: offline 		You really need to tighten the chain on your saw, lol.

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RE: Bell Hop Scratch Build - 1/7/2013 10:56 PM   
Joystick TX



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Status: offline 		Got the wing saddle rough cut made in the fuselage.

Progress is slow, but steady.

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RE: Bell Hop Scratch Build - 1/10/2013 6:07 PM   
Joystick TX



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Received the servos today. Got the HD 1501MG type from Troy Built.

Decided to add a little more dihedral in the wing. Big job filling in the old wing tube holes and drilling new ones.

Still working on getting the wing saddle mated to the wing.




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RE: Bell Hop Scratch Build - 1/11/2013 2:28 AM   
sensei



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quote:

ORIGINAL: Joystick TX


quote:

ORIGINAL: sensei

I am just curious, what is the deciding factor to use the Klegecell over a lighter building material?

Bob


It is cheap and easy to work with, it is also fuel resistant. I started using it many years ago when the price of balsa went out of sight and was hard to get. I could get a 4' x 8' x 1/4'' sheet of Klegecell for $20.

The weight does not seem to be a big issue, so far, my wing weighs 1lb-12oz, without the aluminim wing tube.


You certainly can't get it that cheap anymore so you might want to google a material called Gator board, it can be purchased in 4' x 8' sheets, it's lighter and way more rigid then Klegecell, it has a very thin wood veneer on each side that is very smooth, glueing friendly, and can be covered in Monokote, Ultracote, glass and poly, or Stits covering an paint.

Bob


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RE: Bell Hop Scratch Build - 1/11/2013 3:19 AM   
Joystick TX



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Status: offline 		Thanks, but one of the reasons I like Klegecell is because it is not rigid, it bends easily and cuts like butter. If I need it to be rigid, I can laminate it with fiberglass or wood. Gator board does not meet my requirements.

This is my last scratch-build. I don't like building like I used to. Seems like now I like flying way more than building.


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RE: Bell Hop Scratch Build - 1/11/2013 3:35 PM   
Joystick TX



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Status: offline 		Now at the point where I need to draw out the rudder and elevator outlines full-size. Will use 1/4" x 3/4" balsa to build the parts. Have not decided if I need to "skin" the fixed parts with 1/16" balsa yet to add more strength. Leaning toward yes right now.

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RE: Bell Hop Scratch Build - 1/11/2013 6:21 PM   
a70eliminator


 

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ORIGINAL: Joystick TX

After watching the Red Green marathon for the last two weeks. I think I discovered THE SECRETs to build or repair an airplane so fast.

I've been using the wrong tools. That's why it takes me years to build a plane.

Here is a picture of me using one that I think Red would use to get a nice rounded leading edge.

No, no, no, this is NOT to get the leading edge to a rough shape, this is the "final finishing". I used an Axe to get the rough shape.

Okay, not really. But if you must try this at home, check with your doctor first, make sure your life insurance policy is up to date and please wear proper protection, especially a cup. Don't ask me how I know that last part, it hurts just to think of it.
[/quot

I see a donor engine for power


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RE: Bell Hop Scratch Build - 1/13/2013 2:41 AM   
Joystick TX



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Status: offline 		I tested the HD 1501MG servos today. I like to check the centering or  "zero" by adding a 12" pointer to the servo output. The way they center is a little odd. If the sticks are moved quickly they seem to work normally. They center within about 1/4 degree. If the sticks are moved slowly, they center to around 2 degrees, then after a second or two, they jump and center to within 1 degree. I'm not sure what that will translate to during flight, it may not be noticeable to me as a sport flyer, but I would not use them for serious pattern flying.


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RE: Bell Hop Scratch Build - 1/13/2013 4:01 PM   
Joystick TX



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Status: offline 		Bare bones of the vertical stab and rudder. The stab will be skinned with 1/16" balsa. This part goes pretty quickly. Next will be the horizontal stab and elevator. Not too exciting.

I also added a 1/8" plywood reinforcement to the last rib on the wing joiner tube just to give it some additional support that will not "crush" under the vertical forces on the wing.

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RE: Bell Hop Scratch Build - 1/20/2013 2:39 PM   
Joystick TX



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Status: offline 		Got the tail feathers built up. Need to sand the edges next.

Did some checking on the weight of things to see if it is going to be under or over the design limit. Looks good so far. The wing is 86" and it came in at 2 lbs 8 oz with servos and the heavy (6 oz) wing tube. The fuselage came in at 1 lb 6 oz, need to add the LG, servos, receiver, fuel tank, etc. The tail feathers are 8 oz. The engine and ignition is 2 lbs 4 oz.

So far, without covering and paint, I can account for about 11 lbs. Still under the design weight of 15 lbs, but I do need to be careful and watch what I add from now on.

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RE: Bell Hop Scratch Build - 1/29/2013 7:27 PM   
Joystick TX



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Status: offline 		Trial fit of the tail feathers.

Got some wood filler in the wing saddle to get the wing level with the stab. Will add more later after the wing halves are joined together.

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RE: Bell Hop Scratch Build - 2/2/2013 5:11 PM   
Joystick TX



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Status: offline 		Got the landing gear mounted. Using the LG from the Great Planes Giant Big Stick ARF. Seems like it will work great. Has some flex that will help a lot on our grass field.

Also got the engine firewall bolt holes drilled to get the engine prop shaft centered in the cowl exit. Haven't started work on the cowl yet. Not sure what shape it will be, could be rectangular or round. I am leaning toward rectangular since it will be easier to build and I'm getting tired of building. I would like to fly this thing this year.  

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