smchale

My Feedback: (67)

Good point Kirk. My comment was more directed to highlight the good service from BVM. I'm happy to pay what I do with them because the service I get from them is industry leading. In my mind there is a value in that and I'll pay for that support.

Now get back to building for us, no more excuses!!

k_sonn

My Feedback: (32)

I'm waiting on flap hinging parts that were missing so I can't go any further on the wings. So, its on to the fuse.

1st Photo: The flanges of the front and rear fuse sections were sanded smooth at the seams so they could mate evenly. Holes were opened in the flange of the front fuse section to accept the carbon fiber rods.

2nd Photo: The instruction manual tells you to glue the alignment sticks to the fuse but I used a technique John Redman showed in the BVM F-4 thread. I placed masking tape around the perimeter of the front and rear fuse sections and glued the aligment sticks to the tape with ca.

3rd Photo: Thealuminum recepticles werescrewed tothe plywood tongues and balsa spacers were glued to the back of theplywood tongues.The balsa spacers were sanded to fit against the fuse. Once the fit was found for each recepticle, they were hysoled in place.

Photo 4: After the hysol set, the masking tape and alignment stickes were removed. A perfect fit is the result.

Kirk

k_sonn

My Feedback: (32)

Next up is adding the wing mounting formers into the fuse.

Photo 1: The openings in the wing root area of the fuse were opened.

Photos 2, 3, & 4: Formers F3, F4, and F4A were sanded on both sides with 80 grit. Formers F3 and F4 are end grain balsa sandwiched between carbon fiber. Former F4A is a carbon fiber plate. F4A is glued to the front side of F4. Plywood former F4B is glued to the back side of F4. The wing spar bolt inserts was glued to former F4A with hysol.

Photos 5, 6, & 7: The F3 former and F4 former assembly was placed in the fuse and the wings are put in place. The wings were raised above the the bench so that the fuse does not touch the bench and they are bolted to the F4 former assembly. Tape is used to make sure the leading edge mates correctly to the fuse. F3 is placed against the phonelic tubes an formers and phonelic tubes are hysoled in place.

Photo 8: Lastly, the canopy deck and engine cover hatches areset in palce and tape is used to pull the fuse sides so that they were even with the hatches.

Tomorrow after the hysol has set, the wings will be removed

Kirk

smchale

My Feedback: (67)

Very nice Kirk. Clean work as usual. Looks like having the fuse split makes it a lot easier to work around at this stage.

John Redman

My Feedback: (8)

Kirk, looking awesome!!!

Man from teh last few pics you are almost done!

Keep it rolling sir, looking forward to the next set of pictures.

k_sonn

My Feedback: (32)

Before heading off to work this morning, balsa spacers were glued in place under the phenolic tubes, then former F3A was hysoled in place sandwiching the phenolic tubes between formers F3 and F3A.

Kirk

k_sonn

My Feedback: (32)

Thanks Sean. There is way more room in this fuse compared to the smaller BVMFury i built a couple of years ago. It really is nice being able to work on the front and rear sections of the fuse seperately. As you can see in the photos above, this plane dwarfs my solid core door work bench.

Kirk

k_sonn

My Feedback: (32)

Thanks John. I can see a pin point of light way down at the end of the tunnel, at least for the building. After it's built it will be covered with Flite Metal and that tunnel is pitched black with no light right now

Kirk

John Redman

My Feedback: (8)

Will be awesome. have you found it seems to take a bunch of time to take pictures and post everything.

I am glad to do it, but man, I almost think I could get more building done if you didn't have to.

k_sonn

My Feedback: (32)

Yes, it can be time consuming to take the photos, resize them so you can post them, andthen describe what you did. But if it helps somebody, then its worth the extra effort. I know how you feel though, with the lack of participation in the build threads(or the lack of participation if you aren't in the right clique) and the over participation in the B.S. threads, it can make you feel like it isn't worth the extra effort. If its any consolation, I did learn a thing or two in your F-4 build thread.

Kirk

KC36330

Kirk, FWIW i follow along on a good many build threads (this one from the very start) to see if there are any techniques that are used that i like better then my own. i've enjoyed your build, i was tagging along on Johns F-4s but unsubscribed when there was more talk then building. i don't have the patients to stop and take pics along the way, i like to hit it hard and fast and get as much done in the time i've got to 'Get'r'Done'. enjoying your build, keep up the good work.

roger.alli

Hi Kirk,

May I add my thanks to you and John for posting these builds. I am following it closely and I have learned a lot from both these threads. There is not a lot of BVM airframes built in Australia, so it is very helpful to me, plus the tips that others chime in with..

The BVM manuals are pretty extensive, but there always seems to be different techniques for accomplishing various tasks..



Roger

k_sonn

My Feedback: (32)

Thanks KC and Rodger.  Building is a large part of the hobby for me and if a build thread helps someone, it's worth the extra effort.  I've been building since before arfs became popular and I still learn things from other build threads. 

Kirk

John Redman

My Feedback: (8)

Thanks Kirk,

It is hard to grind every night although I would love to. Family and other things make it one or two nights a week and hopefully some weekend time. I agree as long as it helps someone it is worth it.

Keep it trucking buddy. Looking awesome.

k_sonn

My Feedback: (32)

I received an email today from Germany letting me know the fan will be shipping tomorrow. Below is a photo of it's smaller brother, 120mm DS-77,that powers my Ziroli Panther.

Here are the spec's for the fan:

DS-94-DIA HST with DSM6745-700
Inner diameter: 128 mm
Fan Swept Area: 94 cm^2
Weight including motor: 1330g (2.9 lbs)
Thrust Range: 22.5 to 29.2 lbs (100-130 N)
Exit Velocity (Efflux): 94-108 m / s
RPM: 28,000 - 30,500
Amps: not given but calculated based on cell count and watts: 144A to 182A
Input Watts: 6.6 to 9.7 kW
Number of Cells: 12S to 14S

The DS-94 and the Dynamax are the same size fan so for comparison these are the spec's posted on the XPS website:

XPSDynamax Pro II
Inner diameter: 128 mm
Fan Swept Area: not given
Weight including motor: not given but from other threads it was stated at over 3 pounds
Thrust Range: 29 lbs
Exit Velocity (Efflux): not given
RPM: 36,250
Amps:205A
Input Watts: not given but calculated based on cell count and amps: 12.5 kW
Number of Cells: 16S

So, the comparison shows the following when each fan produces 29 lbs of thrust:
- The DS-94 runs at a lower amp draw than the Dynamax
- The DS-94 runs on 14 cells vs the Dynamax running on 16 cells
- The DS-94 runs at 5750 rpms less than the Dynamax
- The DS-94 consumes 2.8 kW less than the Dynamax
- The DS-94 weighs less than the Dynamax

The comparison shows the DS-94 is a lighter setup (fan weighs less and less number of cells required)with longer flight times (less amp draw and less kw consumed)when carrying the same amount of mAh.

Kirk

smchale

My Feedback: (67)

Nice comparison Kirk, should be a great powerplant. Certainly worth the extra initial cost.

k_sonn

My Feedback: (32)

With the wings mounted, it was time to move to the rear fuselage section.

Photo 1: The carbon fiber formers were prepared by sanding them with 80 grit. The aluminum vertical stab recepticles were screwed in place and the horizontal stab mounting plates were glued together using a plywood jig to set the proper dihedral angle for the horizontal stabs.

Photo 2: The vertical stab has 2 carbon fiber rods sticking out of the bottom that go into the aluminum recpticles so the vertical stab can be attached to the fuse. Holes for the carbon fiber rods and the 2 set screw holes were opened up at their scribed lines. The slots for the horizontalstab mounting tongues were also opened at their scrib lines. The location of the full-sized former is found by placing it into the fuse and putting the forward carbon fiber rod of the vertical stab into the aluminum recepticle. The former is then adjusted until the set screw is even with the hole in the side of the fuse. Once the location is found, I used the stick alignment technique to ensure the vertical stab lined up properly with the fuse.

Photo 3: Next, the set crew was tightened and the former was hysoled in place.

Photo 4: The location of the small, partial former for the rear carbon rod of the vertical stab was found in the same manner as the full sized former and it was hysoled in place.

Photo 5: After the hysol around the vertical stab mounting formers set, the horizontal stab mounting plate was set in place and the stabs were attached to check the fit. Everything fit so the stabs and mounting plate were removed. A bead of hysol was run just above the slots and on the vertical stab formers where the mounting plate touched. Grease was smeared on the mounting plate tongues to prevent hysol from adhereing to them. The mounting plate was installed and the hortizontal stabs were attached and the front of the plate was hysoled to the side of the fuse.

Photo 6: The plywood elevator servo mounting former was hysoled in place.

Photo 7: The final results.

Kirk

JackD

My Feedback: (4)

Man, slow down... this won´t take you through the winter

RCKen.

Me and my new plane. Hope you like it

RCKen

smchale

My Feedback: (67)

Man, just think of how quick this would have been if you rec'd all the parts with the kit! Looking great!
Jack's right, you'll have lots of free time left this winter...I'll send you something to work on.

k_sonn

My Feedback: (32)

After it's built I still need to glass the wings and rudder, cover it with Flite Metal, and paint and detail it. But if all ofthat goes quickly, I have an Avonds 15, Palmer 1/6th scale Cougar, 60" F-100, Avonds F-14, IMPF-104, BVM AFSFury, Skymaster L-39, Yellow Aircraft P-38, Ziroli Hellcat, Ziroli Skyraider, ESM Typhoon, and a Top Flight 1/5th scale Corsair to keep me busy

Kirk

k_sonn

My Feedback: (32)

The missing flap hinging parts didn't slow me down. I just moved on to the next build sequence instead of waiting. Received a call from BVMyesterday letting me know the parts were on the way along with the pylons, gear door kit, cockpit kit, and sliding canopy parts that I recently ordered. The cool thing is, if there are missing parts, a quick phone call and you get taken care of without any hassels.

Kirk

pbusa1400

Looking sweet Kirk. Awesome job.

k_sonn

My Feedback: (32)

Thanks Pablo.  You're welcomed to the sticks anytime.  Any plans to go to BITW 2012?

t_burley

My Feedback: (59)

bring that heap out here next year Kirk for sure for BITW!