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Carden 35% Edge 540 Building question - 3/2/2003 1:06 AM   
Ultrasp99


 

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From: Clay, NY, USA
Status: offline 		Any help from you guy's would be appreciated...

Let me start off first by saying this is my first large scale project. I am building a Carden 35% Edge 540 and plan on putting a DA 100 in front. I have completed the motor box and Truss sides and am ready to glue them together. FYI... I have been reading Steve and Bob's project review on the web.

My questions is: Before I start to glue the fuse together do I need to do anything else first.

I don't have the motor yet so I have NOT drilled any holes in the firewall. Can I do that later?
I would like to set it up for smoke, do I have to make any mods prior to gluing the box to the truss sides?
Do I need to put any supports in the motor box?
Etc...Etc...Etc...

Looking forward to your response.

Thanks, Steve

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Construction Pics of a Carden 35% Edge 540 - 3/2/2003 6:49 AM   
CAPtain232



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From: Waynetown, IN, USA
Status: offline 		It is almost ALWAYS better to have EVERYTHING before you start so you can do "TRIAL" fittings as you progress

It is somewhat difficult to tell you what to do as we do not know what your exact set up is.

Engine mounting holes can and USUALLY are done later.

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Construction Pics of a Carden 35% Edge 540 - 3/3/2003 9:49 AM   
trentmark


 

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Status: offline 		as long as you are not using a 3w 100 you can build it first.
i thought the plane was designed around either the da or 3w and was dissapointed when i had to shave .150 thou off the back of my 3w to get it to fit. if i had ck'd it prior to assy i would have cut .250 off the front of the motor box. the engine was in my h9 cap 232 and i didn't think it nec to ck it first. ooops!! I also mounted my cowl with the supplied plywood but attached it to f2. I didn't care for the gap between the cowl and fuse it showed in the plans. I also went with the 3 8411 huffmeier pull pull setup from sam malone, very nice.
Mark Trent


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Modified Cowl Ring - 3/3/2003 10:33 AM   
Ron Eisner


 

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Status: offline 		This is the final shape of the cowl ring before installation. Blind nuts are for hold down bolts, 2 required each side for 2 pc cowl. Ring is 3/16" ply, top holes are for hatch pins, bottom holes for lower hold down bolts.
Very EZ to do, just trace the outline of F-1 and the hatch. Continue to trim slightly for a perfect flush fit.
Cowl is joined to ring with 30 minute epoxy after scuffing and removing the mold release. Later, a light slurry of epoxy and cut fiber will be added for strength.
Ron

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Mounted Cowl Ring - 3/3/2003 10:37 AM   
Ron Eisner


 

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Status: offline 		Final fit before adding epoxy, chop c/f slurry... very strong.

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Glue for Fuse Foam pieces?? - 3/8/2003 4:48 AM   
Ultrasp99


 

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Status: offline 		Well I have the fuse framed up, it's now time to sheet the Turtle Deck, Bottom pieces, etc...

Just wondering what glue you guy's are using for sheeting these fuse foam pieces? Probond??

I was planning on using Probond with alot of weight. Do you just spread the Probond on the sheeting, spray water on the foam and put in shuck with alot of weight?

How much Probond? (Do you just squeeze on and wipe off with a plastic putty knife?)
How much water?



Thanks, Steve

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Construction Pics of a Carden 35% Edge 540 - 3/8/2003 4:55 AM   
rthorne


 

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Status: offline 		Steve:

While I'm not an expert at it I would suggest probond. I used it on a couple small 40 size wings for practice. I didn't use any water (as I didn't realize I needed too). But I'm guessing just a light mist on the balsa itself would do the trick.

I spoke with Dennis about this and he suggested scraping the propond so you have a light coating on the foam and then use LOTS of weight. That way you get a good bond with minimal weight addition.

If I can find some time this weekend I'll be doing the same thing. I need to start sheeting.

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Construction Pics of a Carden 35% Edge 540 - 3/8/2003 5:18 AM   
CAPtain232



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Status: offline 		I wet a paper towel and ring it. LIGHTLY dampen the surfaces and then spread the PRO BOND thin (excellent stuff)

Use close to 1 pound of weight per 1 sq in of wing. Distribute the weight evenly.

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Construction Pics of a Carden 35% Edge 540 - 5/29/2003 9:57 AM   
rthorne


 

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Status: offline 		Finally, I had the time to get the wings sheeted. I took advantage of the 3 day weekend to lay out my servo wells, build some servo frames which I inserted into wings and then sheeted.

The attached pic is the first wing fully sheeted, out of the shucks and trimmed.

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Construction Pics of a Carden 35% Edge 540 - 5/29/2003 9:58 AM   
rthorne


 

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Status: offline 		And the other half of the wing still in the shuck and untrimmed. I meant to take a picture of all the cinder blocks on top of the wing but I'm not lifting those things back on the table. I used 6 cinder blocks totaling 180 pounds. Probably not enough for the purist but it seemed to do a fine job. I'm very pleased with the outcome.

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< Message edited by rthorne -- Jun 20 2003 1:06AM >

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Construction Pics of a Carden 35% Edge 540 - 6/24/2003 7:34 AM   
rthorne


 

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Status: offline 		I took the week off to have some quality time with my airplane :-).

I received the SWB servo/rudder system from Scott today along with the drill jig. Boy that jig made things easy.

I didn't get much done today as I had one meeting to attend this afternoon but will be hitting it hard tomorrow.

Heres a pic of the servo tray with the Futaba 5301 servo installed. I'm going with one for now and will probably install a second 5301 later. At 6v the servo is rated at 284 ounces of torque. I'm going JR on the rest of the plane but went with the 5301's as two of them will generate nearly 600 ounces of torque. I could have went with 3 JR 8411's but that would have increased the cost quite a bit. For my type of flying the 5301's will do the trick.

More pics to follow this week as construction continues......

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Construction Pics of a Carden 35% Edge 540 - 8/2/2003 10:33 AM   
rthorne


 

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Status: offline 		More Pics. Lots of work done. I didn't have the camera available so I wasn't able to document the progress. But heres where I'm at for now.

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< Message edited by rthorne -- Aug 2 2003 2:50AM >

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Construction Pics of a Carden 35% Edge 540 - 8/2/2003 10:34 AM   
rthorne


 

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Status: offline 		I had to add the pilot. Niether the pilot or canopy are glued in yet. I need to fiberglass the hatch and paint the cockpit. I'll probably just give it the ol' stone finish since I already have a spray can of that stuff laying around.

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< Message edited by rthorne -- Aug 2 2003 2:40AM >

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Construction Pics of a Carden 35% Edge 540 - 8/2/2003 10:40 AM   
rthorne


 

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Construction Pics of a Carden 35% Edge 540 - 8/2/2003 10:41 AM   
wgeffon



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Status: offline 		Looks great Rich!

I talked to DSP builders about my cowl and they said that as soon as I make the cut on the bottom the corners will be much more in-line..


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Construction Pics of a Carden 35% Edge 540 - 8/2/2003 10:42 AM   
rthorne


 

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Status: offline 		The sheeted wings and stabs. The stabs are pretty close to being finished. I just need to cut the hole for the servo well and cut the elevators out.

The wings need to have the leading and trailing edge's shapped, the ends capped and the ailerons cut out.

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Construction Pics of a Carden 35% Edge 540 - 8/2/2003 10:45 AM   
rthorne


 

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Status: offline 		Some cowl shots. Getting the cowl setup on the fuse was a couple nights worth of work. I'll take some pics hopefully tomorrow or sunday with the cowl installed on the fuse.

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Construction Pics of a Carden 35% Edge 540 - 8/2/2003 10:46 AM   
rthorne


 

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Status: offline 		I used Goop glue to secure the plywood cowl ring to the fiberglass. I've never used this stuff, but its real solid and it appears that it will absorb some vibration.

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Construction Pics of a Carden 35% Edge 540 - 8/2/2003 10:48 AM   
rthorne


 

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Status: offline 		Lower portion of cowl.

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