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RE: Dirty Birdy ARF - 8/1/2012 12:38 AM   
pitstop000



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Ralph,

I use a torch to heat it up until it’s easily bendable.

I use metal bars inside and or on the outside of the tubing to make it bend.

I use oak hardwood pieces with a bored hole to clamp in the vise as not to mar the header.

Here are the two torches that I use; if you’re not careful with the heat from the torches you can melt the aluminum.
I have on occasion ruined a header or two using this process ............................


quote:

ORIGINAL: Ralph White

Paul, How did you go about re-bending the header? I was afraid the header might kink if I tried re-bending it.
Ralph White



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RE: Dirty Birdy ARF - 8/1/2012 12:52 AM   
pitstop000



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Ben, the header ends up being too close to the fuse so I needed to tweak it so the pipe could be mounted on the side of the fuse.

 

I put in a balsa block and contoured it for the header fit, then glassed over that. I also contoured the back of the block so you can still fit the stock tank,

but I’m using a 2 oz tank in the location of the stock tank with a 16oz behind that. The NovaRossi 61 is a very thirsty engine when running high rpm.


quote:

ORIGINAL: Strega1

Hey Paul

Thanks for the pics and the info on the DB and Rossi. I'm at a loss on the header. Why did you have to bend it? Was there an obstruction? Does all this grinding weaken the firewal? How are you going to reinforce it and with what? When you are done with this project, please furnish more pics and a blow by blow on how you did this particular cut to the firewall. I'll be doing the same with my project, either the side exhaust w/ Performance Specialties tune muffler, or the RE Rossi and modifications. I'll furnish plenty of photos

Thanks for all the info and the photos.

Ben Cubillos
El Paso, Texas



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RE: Dirty Birdy ARF - 8/1/2012 12:57 AM   
PatternPilot



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Looks good..... with the header tank are you going to put the main tank on the CG ?

scott

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RE: Dirty Birdy ARF - 8/2/2012 6:59 PM   
pitstop000



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Scott, I’m still working out my fuel system on the Test stand, but aiming to put the 16 oz close to the CG if possible with my setup.

 

“HEADER UPDATE”

Even after tweaking the stock NovaRossi header, the clearance that I was looking for could not be achieved, so I cut the exhaust flange off a strait header and bent a new pipe and welded it together. Now I’m back in business, just need to clean up the weld and polish her up. Everything good to go as far as the exhaust.



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RE: Dirty Birdy ARF - 8/3/2012 4:59 AM   
pitstop000



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header done!!, this has put me behind schedule but worth the power the NOVAROSSI 61 produces



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RE: Dirty Birdy ARF - 8/3/2012 1:30 PM   
JeffH


 

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Status: offline 		Did you TIG the header together?

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RE: Dirty Birdy ARF - 8/3/2012 3:01 PM   
PatternPilot



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Status: offline 		looks like paul is going into the header bussiness.....

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RE: Dirty Birdy ARF - 8/3/2012 8:21 PM   
pitstop000



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Ben, more pics of the glassing and how it turned out before paint.

It came out better than I thought for working with a painted fuse, TAPE is your friend!!

I used UFO thin and some accelerator to do the glassing instead of epoxy, very quick and light process.

quote:

ORIGINAL: Strega1

Hey Paul

 When you are done with this project, please furnish more pics and a blow by blow on how you did this particular cut to the firewall. I'll be doing the same with my project, either the side exhaust w/ Performance Specialties tune muffler, or the RE Rossi and modifications. I'll furnish plenty of photos

Thanks for all the info and the photos.

Ben Cubillos
El Paso, Texas



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RE: Dirty Birdy ARF - 8/4/2012 3:33 AM   
pitstop000



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Hey Jeff,

Yes this one was done by Heli Arch/TIG, but I’ve also done them with the aluminum welding rods.


quote:

ORIGINAL: JeffH

Did you TIG the header together?



Scott, need a lot more equipment for such an endeavor.

I can do them if I run out of options.

I just need a more precision bender which I finally have found though.


quote:

ORIGINAL: PatternPilot

looks like paul is going into the header bussiness.....



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RE: Dirty Birdy ARF - 8/5/2012 4:07 PM   
pitstop000



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NovaRossi REX CX61 installation pics.



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RE: Dirty Birdy ARF - 8/5/2012 5:09 PM   
Harv2828


 

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Status: offline 		I have flown my Phoenix 7 arf with the 65 OS and standard muffler. Today's engines are so much better that I really don't think I need a tuned pipe. Goes fast and flys great with eflite electric retracts.

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RE: Dirty Birdy ARF - 8/5/2012 5:23 PM   
jet22b


 

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Very nice setup!!! I wish I still Had my Rossi CX61.
Have fun and we want a flight report, please!!
Sonny
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jet22b

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RE: Dirty Birdy ARF - 8/5/2012 5:36 PM   
Ralph White



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Status: offline 		Paul, What ball links are you using on the throttle and mixture controls at the engine end? How are they connected to the cables?

Ralph

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RE: Dirty Birdy ARF - 8/5/2012 8:34 PM   
landeck


 

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quote:

ORIGINAL: Harv2828

I have flown my Phoenix 7 arf with the 65 OS and standard muffler. Today's engines are so much better that I really don't think I need a tuned pipe. Goes fast and flys great with eflite electric retracts.


Harv, how did you mount the E-Flite nose gear? I have read that people were having problems with the gear electronics failing because of vibration.

Bruce

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RE: Dirty Birdy ARF - 8/5/2012 8:37 PM   
pitstop000



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Status: offline 		Thanks Sonny,
"Flight Report" sure, that's comming up.
This NovaRossi DB and the other OS powered DB will both be at the NECPO event on Sept 8, 2012 in

Farmington CT


Any qualified pilot will have a chance to fly either one at the event.

quote:

ORIGINAL: jet22b

pitstop000
Very nice setup!!! I wish I still Had my Rossi CX61.
Have fun and we want a flight report, please!!
Sonny
aka
jet22b


Ralph, I used Sullivan's #508 flexible cable which includes the brass couplers with 2-56 threads, just silver solder them on and they fit the ball links.
For the Ball links I use the Dubro 181 for the trotle and the Dubro 190 on the mixture control, they also come with solder on 2-56 couplers.

quote:

ORIGINAL: Ralph White

Paul, What ball links are you using on the throttle and mixture controls at the engine end? How are they connected to the cables?

Ralph




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RE: Dirty Birdy ARF - 8/5/2012 8:51 PM   
pitstop000



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Status: offline 		FINALLY DONE !! More pics Guys.

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RE: Dirty Birdy ARF - 8/5/2012 9:23 PM   
jet22b


 

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Status: offline 		Again, very sweet setup!! Thanks for sharing!!

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RE: Dirty Birdy ARF - 8/6/2012 2:04 AM   
AllTheGoodNamesAreTaken



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Status: offline 		Paul, that looks fantastic!!!

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RE: Dirty Birdy ARF - 8/6/2012 4:55 AM   
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Buckle up buddy! That thing is going to haul A$$!! I had the opportunity to fly a ten pounder with the NovaRossi up front. Didn't feel like ten pounds to me. Best of luck on your maiden. Very clean job, by the way.
-Robert

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RE: Dirty Birdy ARF - 8/6/2012 5:31 PM   
hrrcflyer


 

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Status: offline 		Hey Pitstop000,

You have INCREDIBLE skills..... How are you going to attach the pipe to the fuse for support, or are you?

Thanks
David

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RE: Dirty Birdy ARF - 8/6/2012 7:35 PM   
Gene Margiotti


 

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What spinner are you using?

Thanks, Gene

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RE: Dirty Birdy ARF - 8/6/2012 11:18 PM   
pitstop000



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Thanks Guys for all the compliments!

 

“Pipe mount”

 

I’m using a regular DaveBrown tune pipe mount, not the Hush-clamp, I don’t trust O rings for retaining a pipe and rather strap it with a metal zip tie.

 

“Spinner”

Custom moded 2 ¼ Tru-Turn FAI spinner.

 

Here are some pics of the OS 65 AX powered Dirty Birdy, “BD 1”



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RE: Dirty Birdy ARF - 8/7/2012 5:50 AM   
jet22b


 

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Another sweet setup!!! Can I come and hangout in your worshop??? Now that I see how the OS 65AX look in this bird, I will have to make the move get get DB #2, ( when Tower get them back in-stock,), I will go with that setup. I just my buy two DB's and set up #3 with the Evo 60nx with a Jett pipe. I have that setup in a Hangar 9 Jackal and its a blast!!!
Thanks, again for sharing!!!
Sonny
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jet22b

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RE: Dirty Birdy ARF - 8/8/2012 4:02 AM   
pitstop000



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quote:

ORIGINAL: jet22b

pitstop000,
Another sweet setup!!! Can I come and hangout in your worshop???
Sonny
aka
jet22b




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RE: Dirty Birdy ARF - 8/9/2012 3:34 AM   
pitstop000



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Going back to wing joiner, forgot to post this at the time.

 

Here are pics of it all done, used G-flex epoxy for putting it together. One to one by volume or 1.1 to 1 by weight, this epoxy can take flex without cracking like other epoxies once stressed. This was the heavier of the 2 wing joiners so it went into the OS powered Dirty Birdy.

 



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