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Ziroli 92" p-47 build thread

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Old 07-11-2015, 11:19 AM
  #51
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Wings (cont)

Left wing (cont)
Some of Brian's clear template plastic used to make a flap template.


Some 1/64" thick ply CA'ed to the TE of the flap to nearly make it impervious to warping, able to sand to a scale contour and limit hanger rash.


Ditto for the aileron.


Flap and aileron glued to the wing ribs.


Half of the LE left for the LE sheeting.
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Old 07-11-2015, 02:20 PM
  #52
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19 days worth of work:
With 2 flyins cancelled so far this year due to rain, got to have something to do!

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Old 07-12-2015, 07:25 AM
  #53
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Wings (cont)

Seemed like a good time to epoxy the two wings together.


After that cured, the front/back ply spars were glued in.


Some balsa blocks were installed under the front/back wing bolt ply plates for bolt guides.


The TE spar was made from aircraft ply to keep the wing from twisting.


Made notes in the wing so I don't forget anything!
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Old 07-12-2015, 04:24 PM
  #54
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Sam,
Looks awesome as always. Off subject a litle bit but is is about flying. You going to the Ohio Dawn Patrol this year.
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Old 07-13-2015, 03:11 AM
  #55
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Of course.
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Old 07-13-2015, 06:37 AM
  #56
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Wing (cont)

Shear webbed (vertical grain) the spars with scrap 3/32" thick balsa sheeting from the gear outer rib to the wing tips.
Also, added the LE spars to the ailerons.

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Old 07-13-2015, 11:58 AM
  #57
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coming along quickly Sammy! Nice work as always. Hurry up...............October's getting closer! :-)
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Old 07-14-2015, 11:38 AM
  #58
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Thanks, Scott.
Been unusual weather here in SW Ohio for the last month, 70's/low 80's with rain just about every day for the last 4 weeks.
=======================

Wing (cont)

Flaps (cont)
Glued in the end flap ribs (W-3G/8G).


Hinges:
Using G10 hinges. One 1/8" thick on the flap side and two 1/16" thick on the wing side with a 1/8" thick ply sandwiched between the two 1/16" G10's. 4/40 bolts and locking nuts for the pins.


Took several hours to cut all eleven pieces. Even with 30 minute epoxy, only one batch of epoxy per hinge setup with 11 pieces to glue and assembly.


Easiest for alignment leaving the flaps attached to the wing while installing all the hinges. Critical to get all 4/40 bolts aligned along the LE of the flaps.

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Old 07-14-2015, 01:30 PM
  #59
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Wing (cont)

Flaps (cont)
Cuts made into the ribs, prior to assembly, made it easy to separate the flaps from the wing.


Some cleanup of the TE of the wing and rounding over the LE of the flaps.
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Old 07-14-2015, 04:52 PM
  #60
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Looking good!!
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Old 07-15-2015, 06:27 AM
  #61
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Thanks, Ragtop,
==========

Wing (cont)

Ailerons (cont)
Cut the ailerons off the wing and sanded the LE of the ailerons and TE of the wing.


Glued 1/8" thick balsa sheet to the LE of the ailerons and TE of the wing.


Flaps (cont)
LE of the flap ribs rounded in prep for sheeting.


Water added to the outside surface of the 3/32" thick balsa sheet and glued to the LE of the flaps.
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Old 07-15-2015, 01:13 PM
  #62
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Wing (cont)

Flaps/ailerons:
Sanded the LE's of flaps and ailerons. Put some masking tape along the top surface of the ailerons to sand the acute angle LE while not damaging the top sheeting.
Used a dremel drum sander to contour the TE of the wing by the flaps.


Next, hard points for the aileron hinges.


Called Darrell, last week, and got some new wheels and they just came in.
The new ones have 4" rims versus the old 3" with the real wide tire.
The new ones are also thinner, width wise.
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Old 07-16-2015, 05:01 AM
  #63
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Wing (cont)

Ailerons (cont)
Balsa block used for hardpoints in wing and ailerons.
Dubro heavy duty nylon hinges are used.


Slot for hinge is about an 1/8" from top surface and cut at about a 45 degree angle to get to the meat of the hardpoint and also puts the hinge pin at surface level.
Xacto saw blade used to make slot.


Due to curve of outer aileron, that hinge is moved inward.



Some easysand bondo to fill in gap between top sheet and LE.

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Old 07-19-2015, 08:01 PM
  #64
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Sam I like the idea on the flaps for hinging , did you put any brass tube in the G-10 to keep the bolts from cutting the hole oblong ??
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Old 07-20-2015, 04:28 AM
  #65
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6 guns,
No tubing. Got about 80 flights on the 110" F4U and 45 on the 110" P-47 with no wear. Flaps aren't used a whole lot for each flight.
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Old 07-21-2015, 05:39 AM
  #66
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Sam that's way cool ! I have always been told that a small piece of brass tubing needs to be put in to G-10 to keep it from wearing . Thanks for the cool info

Jim
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Old 07-21-2015, 02:51 PM
  #67
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Jim,
Do whatever you're comfortable with.
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Old 07-21-2015, 08:18 PM
  #68
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Thanks Sam, I am enjoying your build and thanks for showing how it's done it looks like it will be a great flyer

Jim
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Old 07-24-2015, 08:20 AM
  #69
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Jim,
While rummaging around, found my old robart P-47 arf ailerons. Put over 300 flights on that model and no wear on the hinge pins and it doesn't even look like G10 as it easily flexes (black part in picture).
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Old 07-24-2015, 02:49 PM
  #70
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WOW Sam that is way cool thanks for showing that you are helping me more than you know

Jim
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Old 07-28-2015, 11:55 AM
  #71
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Wing (cont)
Receiver:
Copied the 110" P-47 over to the 96" to save set up time and binded the receiver.

Flaps (cont)
Some homemade servo trays for HS-645's.


Flap 1/8" thick aircraft ply control horn sandwiched between two 1/8" thick balsa ribs.


TE spar and triangle stock of wing needed trimming for arm clearance.


Hardwood 1/4" square back and 1/4"X1/2" front with 1/8" thick ply for shelf to mount servo tray.
50 degrees put into flaps with servo straight back. 4/40 ball links and 3rd hold is used on servo arm for max torque and 90 degree movement.
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Old 08-01-2015, 12:12 PM
  #72
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Wing (cont)

Flaps:
Boxed in the flap hatch with 1/4 square basswood for the cover and balsa for the wing sheeting support.


Ailerons.
Ditto for boxing in the aileron hatch.


Some homemade servo supports from 1/8" thick L angle aluminum stock, drilled/tapped 2/56 screws for servo hole support and 4/40 screws for L angle to 3/32" thick aircraft ply hatch cover. Some heavy duty 4/40 ball links on the servo side and robarts 4/40 ball control horns on the aileron side using servo hex head screws to secure the control arm to the 3/32" thick aircraft ply plate. The plyplate was glued over the aileron's LE and ribs so the bottom balsa sheeting will be flush with the ply plate. In the past, I have put the balsa sheeting over the ply plate but the control horn can crush the balsa sheeting, even after fiber glassing.
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Old 08-03-2015, 05:43 AM
  #73
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Hay Sam I did something similar to what you are doing to my seafury for the wing flaps works very well but I found that the servos have to be laying in the same direction

Jim
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Old 08-04-2015, 12:11 PM
  #74
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Jim,
Ditto for the elevators.

This is how I set mine up

http://blueballfixed.ytmnd.com/
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Old 08-05-2015, 10:47 AM
  #75
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Wing (cont)

Shear webbed both sides of the main spar using 1/32" thick aircraft ply (easy to cut with scissors) and a forstner bit to put holes in them.

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