RE: 2 for one - Carden 40% Extra 300 Build

RE: 2 for one - Carden 40% Extra 300 Build
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RE: 2 for one - Carden 40% Extra 300 Build - 11/28/2007 11:15:29 PM

capflyr

Posts: 130
Joined: 12/13/2004
From: loxahatchee, FL, USA
Status: offline

I wish you lived next door to me I would love to have you build me one, keep up the good work, this is the first fourm I check when I get home.

(in reply to kregan)

Post #: 176

RE: 2 for one - Carden 40% Extra 300 Build - 12/1/2007 2:14:42 AM

kregan

Posts: 1673
Joined: 11/5/2004
From: Highland, MD, USA
Status: offline

capflyr...
Maybe when I retire I will build Cardens for extra cash!

Gripe ON.....
I was going to type a long thing about that block of foam Carden gives you to sand,
shape, and sheet with balsa, without a shuck, but you already know!!
Grip OFF......

Now lets get on with solving that issue.

First I sanded the provided block of foam to shape. Next I made 1/16" balsa templates
of each end. I then sanded 1/16" off the balsa templates were the sheeting will be glued
to the foam.

I duplicated these templates in sheet aluminum. Notice I added 1/2" to the aluminum
so the hot wire would have a place to start.

I drilled holes in the templates and used nails to hold them on. I used the left over foam
the came packed with the wings for the parts.

I fired up my professional foam cutter and gave it a shot! Worked great! The second one
hit the trash, the third one was better then the first.

Now I have parts that fit, and shucks to sheet them in

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< Message edited by kregan -- 12/1/2007 3:48:07 PM >

_____________________________

Kelly
Flying at FSA? We got your B.A.C.C. !!!

(in reply to capflyr)

Post #: 177

RE: 2 for one - Carden 40% Extra 300 Build - 12/1/2007 4:05:06 AM

MTK

Posts: 517
Joined: 5/14/2004
From: Whippany, NJ, USA
Status: offline

quote:

ORIGINAL: kregan

capflyr...
Maybe when I retire I will build Cardens for extra cash!

Gripe ON.....

I was going to type a long thing about that block of foam Carden gives you to sand,
shape, and sheet with balsa, without a shuck, but you already know!!

At least provide a cross section drawing of both ends of the part so we can make a
templates to sand to.

Grip OFF......

Now lets get on with solving that issue.

First I sanded the provided block of foam to shape. Next I made 1/16" balsa templates
of each end. I then sanded 1/16" off the balsa templates were the sheeting will be glued
to the foam.

I duplicated these templates in sheet aluminum. Notice I added 1/2" to the aluminum
so the hot wire would have a place to start.

I drilled holes in the templates and used nails to hold them on. I used the left over foam
the came packed with the wings for the parts.

I fired up my professional foam cutter and gave it a shot! Worked great! The second one
hit the trash, the third one was better then the first.

Now I have parts that fit, and shucks to sheet them in

Kelly,

Just saw this thread and read through some of early parts. Very nice and professional.

You asked a question regarding the amount of weight required for sheeting a wing. You may have gotten the suggestion I am about to give so pardon the interruption if it's been discussed.

300 lbs of weights for a 750 sq inch panel is less that 1/2 psi of pressure load on the husk, plus its a heck of a lot of work to actually do. You might consider using vacuum bagging next time you sheet a wing. It's very easy to do. Minimal vacuum of around 6 inches mercury is about 1/5 atmosphere of pressure, or around 3 psi. Depending on how you apply vacuum, you can get better contact between sheeting and foam using vacuum.

There are details of course. If interested, let me know

MattK

(in reply to kregan)

Post #: 178

RE: 2 for one - Carden 40% Extra 300 Build - 12/1/2007 5:14:15 AM

aviti

Posts: 681
Joined: 12/3/2002
From: Ballwin, MO, USA
Status: offline

Rather than shape that lower rear piece, I used the rear of the leftover belly pan shuck. It's the same shape so you just pick the width that you need and sheet it. You can make it a bit longer and then sand it to fit. I'm talking about the inner part of the shuck by the way...

(in reply to MTK)

Post #: 179

RE: 2 for one - Carden 40% Extra 300 Build - 12/2/2007 12:24:42 AM

kregan

Posts: 1673
Joined: 11/5/2004
From: Highland, MD, USA
Status: offline

Matt,
Kurt, the owner of the second plane has a access to a vacuum bagger
but since this was my first time sheeting wings I wanted to keep it simple.
Next time I would have no problem trying it and I understand it works great.

Dick Hanson uses a vice/clamp arrangement made from steel bars and
all thread rod. I was going to try that also.

Aviti,
I never thought about that.... Today when I looked at my inner shucks
from the rear deck it was to large to work without reshaping.
__

I glued the bottom deck onto both planes and sheeted the parts I cut last
night.

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_____________________________

Kelly
Flying at FSA? We got your B.A.C.C. !!!

(in reply to aviti)

Post #: 180

RE: 2 for one - Carden 40% Extra 300 Build - 12/2/2007 3:55:39 AM

MTK

Posts: 517
Joined: 5/14/2004
From: Whippany, NJ, USA
Status: offline

quote:

ORIGINAL: kregan

Matt,
Kurt, the owner of the second plane has a access to a vacuum bagger
but since this was my first time sheeting wings I wanted to keep it simple.
Next time I would have no problem trying it and I understand it works great.

Dick Hanson uses a vice/clamp arrangement made from steel bars and
all thread rod. I was going to try that also.

Aviti,
I never thought about that.... Today when I looked at my inner shucks
from the rear deck it was to large to work without reshaping.
__

I glued the bottom deck onto both planes and sheeted the parts I cut last
night.

Years ago I used to use the clamp and bolt method but was never sure what pressure I was applying to any specific area of a wing panel. I used stops on the plattens and tightened against them. Never had a failure so this method works fine

Vacuum assures even pressure everywhere. FWIW

MattK

(in reply to kregan)

Post #: 181

RE: 2 for one - Carden 40% Extra 300 Build - 12/4/2007 12:06:30 AM

kregan

Posts: 1673
Joined: 11/5/2004
From: Highland, MD, USA
Status: offline

Worked on the lower deck extension parts. Once sheeted I used the
shuck to hold the part while I cut off the removable hatch portion.

I made and epoxied in 1/8" ply plates to hold the 6/32" blind nut
for the hatch. I will only be using 1 6/32 screw to hold the hatch
in place. More pictures of that after the glue dries.

Last 2 pictures illustrates how the 1/16" x 3/4" balsa strips form the
gusset plates all the cross bracing. I talked about this in message
118, page 5 when I was sheeting parts.

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_____________________________

Kelly
Flying at FSA? We got your B.A.C.C. !!!

(in reply to MTK)

Post #: 182

RE: 2 for one - Carden 40% Extra 300 Build - 12/5/2007 12:50:30 AM

weathervane

Posts: 1239
Joined: 6/8/2006
From: Baltimore, MD, USA
Status: offline

Kelly, You have made some great progress. Your work is flawless. I really enjoy following the build.

-Andrew

_____________________________

Without trucks, America stops.
www.freestateaeromodelers.org

(in reply to kregan)

Post #: 183

RE: 2 for one - Carden 40% Extra 300 Build - 12/5/2007 12:53:16 AM

kregan

Posts: 1673
Joined: 11/5/2004
From: Highland, MD, USA
Status: offline

Removable rear hatch is complete on both planes.
Only thing left is the built up balsa sides next to
the tail gear mounting location.

I don't have the tail wheels so I need to get some
dimensions from Kurt. Really all I need is the width
of the his tail wheel.

I'm am guessing 7/8" to 1" wide.

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_____________________________

Kelly
Flying at FSA? We got your B.A.C.C. !!!

(in reply to kregan)

Post #: 184

RE: 2 for one - Carden 40% Extra 300 Build - 12/5/2007 1:08:16 AM

kregan

Posts: 1673
Joined: 11/5/2004
From: Highland, MD, USA
Status: offline

Thanks Andrew,

The great thing about a digital camera.... you can delete the pictures
that show the flaws!

If I had the rear deck to do over again I would glue the foam block
onto the the bottom deck before sheeting it. I would splice some
sheeting together and sheet it as one piece. Then cut the hatch out
of that.

quote:

ORIGINAL: weathervane

Kelly, You have made some great progress. Your work is flawless. I really enjoy following the build.

-Andrew

_____________________________

Kelly
Flying at FSA? We got your B.A.C.C. !!!

(in reply to weathervane)

Post #: 185

RE: 2 for one - Carden 40% Extra 300 Build - 12/5/2007 1:09:26 AM

KF3CW

Posts: 21
Joined: 2/13/2003
From: Silver Spring, MD, USA
Status: offline

Kelly,

I just measured Kurt's 40% Carden.: The tailwheel is 7/16" and the tailwheel bracket width is 3/4". It is a real small tailwheel.

_____________________________

Papa K

(in reply to kregan)

Post #: 186