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Jerry Bates Hellcat - 11/13/2002 10:06 PM   
k_sonn



Posts: 1357
Score: 100
Joined: 2/15/2002
Last Login: 11/6/2009
From: Bellevue, WA, USA
Status: offline 		I will be building a Jerry Bates Hellcat. I will post construction notes and photos as I go along.

Specs:
Scale -- 1/6.42
Wing span -- 80 inches
Length -- 62 inches
Wing Area -- 1166 square inches
Weight -- 18 to 22 pounds

List of Products Used:
Engine -- ?
Main Retracts -- Century Jet
Tail Wheel Retract -- Earl Aune
Plans -- Jerry Bates
Cut wood parts -- Semi kit laser cut by Bob Holman
Misc Wood -- Lone Star Balsa
Cowl -- Bob Holman

Canopy -- Bob Holman
Cockpit Kit -- Dynamic Balsa
Radio -- JR 8103
Servos -- ?
Bellcranks -- Nelson Hobby
Glue -- Zap CA, Titebond II Wood Glue

The picture below is the scheme I will use.

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< Message edited by k_sonn -- Aug 15 2003 5:46PM >

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Wing Center Section - 11/15/2002 9:34 PM   
k_sonn



Posts: 1357
Score: 100
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Last Login: 11/6/2009
From: Bellevue, WA, USA
Status: offline 		I started building the wing for the Bates Hellcat last night. Construction is pretty straight forward. The following is the order of the steps I performed:
- Glue the two number 1 ribs together.
- Glue ribs 1 through 4 on the two plywood dihedral braces.
- Add the servo tray before you add the number two ribs, but do not glue at this time.
- Glue the 1/4 x 1/2 spruce main spar.
- Glue the 1/4 x 1/4 main bottom spar. (NOTE: The plans call for a 1/4 x 1/4 balsa spar for the main bottom spar. I used spruce instead of balsa).
- Glue the front top 1/4 x 1/4 balsa spar.
- Glue the rear top and bottom 1/4 x 1/4 balsa spars.
- Glue 1/16 shear webbing to the top and bottom rear spars between the ribs.
- Glue 3/32 rib caps to the front of the ribs.
- Glue servo tray in place.

All of the parts fit together perfectly.

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< Message edited by k_sonn -- Nov 19 2002 5:17PM >

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Jerry Bates Hellcat - 11/15/2002 9:35 PM   
k_sonn



Posts: 1357
Score: 100
Joined: 2/15/2002
Last Login: 11/6/2009
From: Bellevue, WA, USA
Status: offline 		Wing Center Section #2

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Jerry Bates Hellcat - 11/15/2002 9:36 PM   
k_sonn



Posts: 1357
Score: 100
Joined: 2/15/2002
Last Login: 11/6/2009
From: Bellevue, WA, USA
Status: offline 		Wing Center Section #3

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Jerry Bates Hellcat - 11/15/2002 9:36 PM   
k_sonn



Posts: 1357
Score: 100
Joined: 2/15/2002
Last Login: 11/6/2009
From: Bellevue, WA, USA
Status: offline 		Wing Center Section #4

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Wing Right Panel - 11/19/2002 10:16 PM   
k_sonn



Posts: 1357
Score: 100
Joined: 2/15/2002
Last Login: 11/6/2009
From: Bellevue, WA, USA
Status: offline 		This weekend the right wing panel was built. These are the steps I followed:
- Laminated 1/16 balsa sheeting to 1/32 plywood to make wing sheeting trailing edge in the flap area.
- Cut to length and shape and glued the laminated wing sheeting trailing edge in the flap area.
- Glued sheeting to the top of the wing center section.
- Glued plywood #5 rib to balsa #5 rib.
- Glued #5 rib to the two plywood dihedral braces.
- Glued retract plywood mount plate between ribs #4 and #5.
- Cut the 1/2 x 1/4 main upper spar at an angle so the 1/4 x 1/4 main spar could be attached.
- Pinned the 1/4 x 1/4 main lower spar over the plans (Note: Plans show 1/4 x 1/4 balsa for the lower main spar but I used spruce).
- Propped the wing center section at an angle so the the main dihedral brace from rib #5 outward was flat on the building surface. (Note: The construction notes on the plans state to prop the wing center section 2 1/2 inches under the first dihedral brace. What the plans did not say was where the 2 1/2 inches should be measured).
- Glued rib #6 to the two plywood dihedral braces.
- Pinned ribs #7 through #13 to the building surface over the lower main spar.
- Glued ribs #5 through #13 to the lower main spar.
- Glued the upper main spar to ribs #5 through #13 (Note: Plans show 1/4 x 1/4 balsa for the upper main spar but I used spruce).
- Glued 1/4 x 1/4 upper and lower trailing edge spars to the ribs.
- Glued a strip of carbon fiber over the upper main spar.
- Glued a strip of carbon fiber over the upper trailing edge spar where the wing curves upward.
- Glued 3/32 rib caps to the front of the ribs.
- Glued 1/16 shear webbing to the top and bottom trailing edge spars between the ribs.
- Glued 1/16 shear webbing to the front and back of the top and bottom main spars between the ribs.
- Glued triangle stock re-enforcement in all corners in the landing gear area between ribs #4 and #5.
- Laminated 1/16 balsa sheeting to 1/32 plywood to make wing sheeting trailing edge in the flap area.
- Cut to length and shape and glued the laminated wing sheeting trailing edge in the flap area.
- Glued sheeting to the top of the right wing panel.

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< Message edited by k_sonn -- Nov 19 2002 11:42PM >

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Jerry Bates Hellcat - 11/20/2002 4:42 AM   
k_sonn



Posts: 1357
Score: 100
Joined: 2/15/2002
Last Login: 11/6/2009
From: Bellevue, WA, USA
Status: offline 		Wing Right Panel #2

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Jerry Bates Hellcat - 11/20/2002 4:43 AM   
k_sonn



Posts: 1357
Score: 100
Joined: 2/15/2002
Last Login: 11/6/2009
From: Bellevue, WA, USA
Status: offline 		Wing Right Panel #3

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Jerry Bates Hellcat - 11/20/2002 4:44 AM   
k_sonn



Posts: 1357
Score: 100
Joined: 2/15/2002
Last Login: 11/6/2009
From: Bellevue, WA, USA
Status: offline 		Wing Right Panel #4

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Jerry Bates Hellcat - 11/20/2002 4:45 AM   
k_sonn



Posts: 1357
Score: 100
Joined: 2/15/2002
Last Login: 11/6/2009
From: Bellevue, WA, USA
Status: offline 		Wing Right Panel #5

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Jerry Bates Hellcat - 11/20/2002 4:45 AM   
k_sonn



Posts: 1357
Score: 100
Joined: 2/15/2002
Last Login: 11/6/2009
From: Bellevue, WA, USA
Status: offline 		Wing Right Panel #6

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Jerry Bates Hellcat - 11/20/2002 4:46 AM   
k_sonn



Posts: 1357
Score: 100
Joined: 2/15/2002
Last Login: 11/6/2009
From: Bellevue, WA, USA
Status: offline 		Wing Right Panel #7

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Jerry Bates Hellcat - 11/20/2002 7:15 AM   
CAPtain232



Posts: 2467
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Joined: 12/15/2001
Last Login: 4/25/2009
From: Waynetown, IN, USA
Status: offline 		Looking very good... Keep us posted


Jeff

_____________________________

CUSTOM GIANT SCALE BUILDER
PROTOTYPE MODEL BUILDING for full scale aircraft
current project can be seen at http://www.geversaircraft.com

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Jerry Bates Hellcat - 11/25/2002 10:37 PM   
k_sonn



Posts: 1357
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Joined: 2/15/2002
Last Login: 11/6/2009
From: Bellevue, WA, USA
Status: offline 		Thanks Jeff.

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Left Wing Panel - 11/25/2002 10:40 PM   
k_sonn



Posts: 1357
Score: 100
Joined: 2/15/2002
Last Login: 11/6/2009
From: Bellevue, WA, USA
Status: offline 		This weekend the left wing panel was built. These are the steps I followed:
- The same steps taken for building the right wing panel were followed to build the left wing panel.

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< Message edited by k_sonn -- Nov 26 2002 7:02AM >

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Jerry Bates Hellcat - 11/26/2002 12:03 PM   
k_sonn



Posts: 1357
Score: 100
Joined: 2/15/2002
Last Login: 11/6/2009
From: Bellevue, WA, USA
Status: offline 		Left Wing Panel #2

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Jerry Bates Hellcat - 11/26/2002 12:04 PM   
k_sonn



Posts: 1357
Score: 100
Joined: 2/15/2002
Last Login: 11/6/2009
From: Bellevue, WA, USA
Status: offline 		Left Wing Panel #3

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Jerry Bates Hellcat - 11/26/2002 12:05 PM   
k_sonn



Posts: 1357
Score: 100
Joined: 2/15/2002
Last Login: 11/6/2009
From: Bellevue, WA, USA
Status: offline 		Left Wing Panel #4

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Jerry Bates Hellcat - 11/26/2002 12:05 PM   
k_sonn



Posts: 1357
Score: 100
Joined: 2/15/2002
Last Login: 11/6/2009
From: Bellevue, WA, USA
Status: offline 		Left Wing Panel #5

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Jerry Bates Hellcat - 11/26/2002 12:06 PM   
k_sonn



Posts: 1357
Score: 100
Joined: 2/15/2002
Last Login: 11/6/2009
From: Bellevue, WA, USA
Status: offline 		Left Wing Panel #6

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Fuse, Vertical & Horizontal Stabs - 12/3/2002 10:47 PM   
k_sonn



Posts: 1357
Score: 100
Joined: 2/15/2002
Last Login: 11/6/2009
From: Bellevue, WA, USA
Status: offline 		I was planning on having several days of building time during the Thanksgiving Holiday. Well the best laid plans do not always work out. I did not get to spend any time building on Thursday. Friday was the wife's birthday so I gave her that day. Saturday was one of the best flying days we have had in the Northwest in long time so I spent the day flying. That left Saturday night and Sunday during the day and the evening (I had to watch the Seahawks get their backsides kick).

Vertical & Horizontal Stabilizers
I needed to order some bell cranks from Nelson Hobby so I elected to put the wing aside for now and started working on the vertical and horizontal stabs. The build process for both is the same; build one half of it flat on the building board, sheet it, then flip it over and build the other half and sheet it. This was completed on Saturday night.

Fuselage Crutch
Also on Saturday night I built the fuselage crutch. The crutch has two plywood sides that go to 6th former. The plywood top goes from the firewall to the instrument panel former. The firewall is 1/4 inch plywood. There is a small bottom section that I did not glue on yet because I wanted the crutch to sit flat on the building board when the formers were added. Triangle stock is used in all of the inside corners of the crutch. Epoxy was used to glue all the sections of the crutch together.

Fuselage
The following steps were used in building the fuse:
- The crutch was placed over the plans and pinned in place.
- Formers 1 through 6 were added to the crutch.
-Formers 1 through 6 were all cut about an 1/8 of an inch too wide on the inside (the area that is supposed to fit on the crutch snuggly). I filled the gap on each side of the each former with 1/16 ply and then added triangle stock on each side of the former for added security.
- Pinned formers 7 through 12 to the building board over their location on the plans.
- Ran 1/4 x 1/4 stringers (alternating sides so that everything stayed straight and true).
- Glued the top fuse spine in place.
- Glued horizontal stab saddles in place.
- Sheeted fuse.

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< Message edited by k_sonn -- Dec 4 2002 4:03AM >

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Jerry Bates Hellcat - 12/4/2002 9:04 AM   
k_sonn



Posts: 1357
Score: 100
Joined: 2/15/2002
Last Login: 11/6/2009
From: Bellevue, WA, USA
Status: offline 		Vertical Stab #2

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Jerry Bates Hellcat - 12/4/2002 9:05 AM   
k_sonn



Posts: 1357
Score: 100
Joined: 2/15/2002
Last Login: 11/6/2009
From: Bellevue, WA, USA
Status: offline 		Fuse #1

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Jerry Bates Hellcat - 12/4/2002 9:06 AM   
k_sonn



Posts: 1357
Score: 100
Joined: 2/15/2002
Last Login: 11/6/2009
From: Bellevue, WA, USA
Status: offline 		Fuse #2

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Jerry Bates Hellcat - 12/4/2002 9:07 AM   
k_sonn



Posts: 1357
Score: 100
Joined: 2/15/2002
Last Login: 11/6/2009
From: Bellevue, WA, USA
Status: offline 		Fuse #3

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