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Super Falcon Build - 5/16/2009 8:34 PM   
R Verbael


 

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From: Yuma, AZ, USA
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OK guys....you have asked for it, so here goes.  If the build seems to be in the wrong forum, please let me know.

As I posted, I have admired the Falcon series airplanes for 40 years and just recently lost a really great flying Senior Falcon ARF.  So, after I thought about it for a while, I decided to scratch out a 25% larger Senior Falcon....hence Super Falcon.

A friend had a partial set of Senior Falcon plans and after a trip to Office Max, i now have the expanded plans.  I cut out fuse doublers from 1/8" oak plywood and notched the first 3  plywood bulkheads so that the doubler and bulkheads would be locked together mechanically as well as glued.  Next step is to glue 1/4" balsa fuse outer skin to the doubler and then glue up these parts as an assembly.  Time invested: 4 hrs.  Total time:6 hrs.

Pics show the Senior Falcon and Super Falcon fuse profiles compared, and the doubler/bulkheads fit up.



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< Message edited by R Verbael -- 5/16/2009 8:41 PM >

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RE: Super Falcon Build - 5/16/2009 8:54 PM   
iflyj3



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Status: offline 		What do you plan on powering it with?

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RE: Super Falcon Build - 5/17/2009 12:07 AM   
gittarpikk



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quote:

ORIGINAL: iflyj3

What do you plan on powering it with?


Hi iflyj3

He mentioned on another thread that he is planning on using a Supertiger 2300

thread here
http://www.rcuniverse.com/forum/m_8765637/tm.htm

and there were some good pics of the original senior falcon
This will be a great plane to supersize...ought to fly very good.






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RE: Super Falcon Build - 5/18/2009 2:43 AM   
Aurora_60



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From: kaneohe, HI, USA
Status: offline 		Oh I can't wait.
I'll need a nice cup of coffee and a soft chair...
ok I'm ready , Bring on the Build thread!!





DM

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RE: Super Falcon Build - 5/18/2009 7:06 PM   
R Verbael


 

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2nd Build Report:

I took the firewall and mounted an engine mount, nose gear bracket and then cut  fuse sides out of 1/4" balsa.  I then glued up triangular corner longerons into the aft fuse edges.  I used Titebond to glue the doublers to the fuselage sides.  To ensure the whole assembly would turn out straight and true, I layed out a centerline on my assembly table (solid core door), and made up triangular jigs that will ensure the beast is not twisted or warped.  Just prior to commiting to firewall and bulkhead glue (epoxy), I verified that I had a couple of degrees of right thrust built into the firewall/engine mount.  Super Tigre 2300 looks good sitting up front!

Time for these processes: 10 hrs.  Total time in the project: 16 hrs.  (Does not count time to and from the LHS, does count lots of itching and scratching time)

Fuse tops and bottoms are next.

Comments are most welcome.
 



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< Message edited by R Verbael -- 5/18/2009 8:53 PM >

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RE: Super Falcon Build - 5/20/2009 6:23 AM   
R Verbael


 

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From: Yuma, AZ, USA
Status: offline 		Build Report #3

The aft ends of the fuse were pulled together and glued using a tapered tailpost piece to make the fuselage taper fit and offer lots of meat for the glue to take hold.  I then used a 48" piece of 3/16" Balsa to form the full fuse floor from the tail post to the #2 bulkhead.  Once glued in, the fuse has now taken on lots of internal strength and can easily be moved in and out of the jig fixtures.  These fixtures and a bold centerline have really helped keep everything true.  The flooring between the firewall and #2 bulkhead (tank compartment)  was roughed in using a 1/2" piece of balsa that was mostly sanded away, yielding the famous Falcon chin upsweep.   

I have left the top of the fuse open while I decide just how to run pushrods.  I installed the #4 and #5 bulkheads at this time.

The horizontal stab was layed out, ribs cut and fit, and the assembly was sheeted.  Following this, wingtips were glued in place and sanded to final rough shape. 

Process time in this report:  10 hrs.  Total project time: 26 hrs.

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< Message edited by R Verbael -- 5/20/2009 6:25 AM >

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RE: Super Falcon Build - 5/20/2009 8:01 AM   
Aurora_60



Posts: 437
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From: kaneohe, HI, USA
Status: offline 		In your last picture (#6) I think I see an old school Crager 5 hole wheel. Whats that all about??
Sorry for getting off topic everyone, but I just have to know.

This build is comming along fast!
Very nice work and thanks for sharing. I know how much extra work goes in having to take pictures and post them, but we are all enjoying your labor!
Any ideas on the color schemes yet??

DM

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RE: Super Falcon Build - 5/20/2009 2:31 PM   
R Verbael


 

Posts: 26
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From: Yuma, AZ, USA
Status: offline 		I must confess anal attachments to "long-ago" memories, habits, favorite things.....which includes my old high school hot rod that is still part of my life after nearly 50 years.  4 motors, at least 4 paint jobs, but it is still MINE and still operating.  My wife and I drove it to the St Paul (Minn) Street Rod Nats a few years ago.  Pretty sharp eyes,. Aurora 60.

I am trying to get enough gumption to start on the Falcon wing panels....maybe this week.

Russ V.

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< Message edited by R Verbael -- 5/20/2009 2:34 PM >

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RE: Super Falcon Build - 5/24/2009 3:30 AM   
R Verbael


 

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From: Yuma, AZ, USA
Status: offline 		Build Report #4   (Starting on the Wing)

I glued up spars, per Goldberg Falcon methods, and then cut out 32 ribs on my trusty jig saw.  I made two stacks of 16 ribs, pinned them together, and sanded them to an identical airfoil shape.  I think that the Falcon's really great flying qualities can be partially  attributed to accurate wing and stab that came from all the interlocking features in the original kit.  I want to keep everything straight and true in this project.
I notched out the leading and trailing edge stock and then took a chance on cutting out the spar holes in the ganged up ribs.  Seemed to work, but I had to be in the right mood......not in any hurry, etc.
So I now have the first wing panel  dry fit.  Seems to look OK.  On to gluing and sheeting in the next report.

Time for this process:  8 hrs.  Total time in the project 34 hrs.



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RE: Super Falcon Build - 5/31/2009 8:38 PM   
R Verbael


 

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Status: offline 		Build Report #5

I recut the inner 7 ribs with a forsner bit to create  carry-through tunnelling for aileron servo wiring...actual tunnel material was cardboard rolled up from a cut-up file folder.  The inner 5 ribs were recut to allow for dihedral braces/wing joining doublers.  NOW, I am gluing up the leading, trailing edges, and the outer ribs to the spars.  No glue has been applied to the spar-inner ribs until I get the second wing panel built and ready to  be joined.  Time into this process, 3 hrs;  Total project time, 37 hrs.

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RE: Super Falcon Build - 5/31/2009 10:44 PM   
Johnkpap



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From: Adelaide, AUSTRALIA
Status: offline 		I was flying my Scratch built Snr Falcon this weekend,  mine is a standard size Very Over  Powered by a Webra 61.

I have been flying it for some time,  as a Aerobatics trainer, after completing a number of inside loops, it was not flying quite right.

I bought her in for a not so perfect landing, after retreving my model I inspected the wings and noticed some movement inside the wing.

I decided it was time to go home and check my model:- >> I found I had cracked a spar !!! I have glued the balsa back together and added thin ply  as webbing to
re-enforce things around the 4-5 inch point of the main spar

As yours is scaled up you may like to do the same to re-enforce things.

Johnkpap

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RE: Super Falcon Build - 6/10/2009 6:29 AM   
R Verbael


 

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Status: offline 		  John...great advice.

Many years ago, I was flying a Falcon 56 with my son and I let him take the controls and do "anything he wanted"....he made a screaming dive that ended with an outside loop and folded the wings!  The crash was pretty nasty, so an accurate analysis of just what failed was impossible, but I think the spars broke out about where the wing sheeting ends.

I am definately planning to increase the spar strength on my Super Falcon.

Russ V.

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RE: Super Falcon Build - 6/10/2009 1:16 PM   
BobHH



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Status: offline 		Yep, on the Falcon 56 and Sr Falcon re-issue kits for Early RC Models I modified the spar to use spruce caps both top and bottom of the main spar.  The original balsa spars were a bit weak. Years ago when I was a lad a friend built a Falcon 56 and asked me to maiden it. About 10 feet off the ground during takeoff the wing folded. Upon inspection it did not have the plywwod dihedral braces between the wings. His comment was he forgot and did not think they were needed!!! He is a mechanical engineer now!!!!!

Bob Harris

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RE: Super Falcon Build - 6/15/2009 6:34 AM   
lylec


 

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From: So. Sioux City, NE, USA
Status: offline 		I am looking for the plans for the senior falcon, How much would you charge for a copy or how much you've done so far. lylec@longlines.com

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RE: Super Falcon Build - 6/29/2009 4:03 PM   
fireman7875


 

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quote:

ORIGINAL: BobHH

Yep, on the Falcon 56 and Sr Falcon re-issue kits for Early RC Models I modified the spar to use spruce caps both top and bottom of the main spar.  The original balsa spars were a bit weak. Years ago when I was a lad a friend built a Falcon 56 and asked me to maiden it. About 10 feet off the ground during takeoff the wing folded. Upon inspection it did not have the plywwod dihedral braces between the wings. His comment was he forgot and did not think they were needed!!! He is a mechanical engineer now!!!!!

Bob Harris



Bob, hmmm, a "friend"? Are you sure it was a friend? Aren't YOU a mechanical engineer?

Brian

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RE: Super Falcon Build - 6/29/2009 9:59 PM   
BobHH



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Status: offline 		Hey Brian! Long time no see/hear from!!! At the time of that test flight I was 12 years old!! That was a gazillion years ago!!!

Bob Harris

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RE: Super Falcon Build - 7/5/2009 5:37 PM   
flyroger


 

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From: Mason, OH, USA
Status: offline 		I am looking for a copy of the origional Sr. Falcon plans. Anybody can help? Roger

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RE: Super Falcon Build - 7/5/2009 6:00 PM   
Johnkpap



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Status: offline 		Yes I have one

Mine is the very early version, Bought back in the 80's from a shop that was closing down It shows the wing and tail rib,it is easy to build from.

Mine has flowen many times over the past 3 years, first with a OS 50 FSR now it is over powered by a old Weber 61 from the 1960's, I will be building
a new wing soon as mine is starting to have stress issues, from pulling too many G's.

PM me and we can work out a deal.

Johnkpap


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RE: Super Falcon Build - 10/24/2009 7:59 PM   
neilmac52


 

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From: burnham , UNITED KINGDOM
Status: offline 		Hi there i am trying to follow your .SUPER Falcon build. What has happend it stoped ? At post 5 is it flying yet ? Please update

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RE: Super Falcon Build - 11/4/2009 10:12 PM   
Arcee


 

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Can anyone explain the performance differences between each one of these Saitos if they were flown in the classic Sr. Falcon (69" wing span - 810 sq in): Saito 56 (original version), Saito 62a and the Saito 65 (original version)?


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RE: Super Falcon Build - 11/5/2009 12:39 PM   
Arcee


 

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.....I have also been following the Super Falcon build.........what's the latest?


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