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Vailly Seafury 90 inch - new wing build

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Old 04-18-2016, 07:29 PM
  #1
planenutzz
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Default Vailly Seafury 90 inch - new wing build

busted the wing a while back and only just getting around to building a new one. Wing kit by PCK, less said about that the better.

A few photos to document progress which is quite slow as I figure out the build.

thanks
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Old 04-18-2016, 07:43 PM
  #2
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more photos f Ican get it to upload them.
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Old 04-21-2016, 03:00 PM
  #3
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Little bit of progress, been sidetracked with other matters.

Must say that Roy V has been very helpful giving advice on this wing build, it is not as stright forward as it may seem.

starboard outer wing panel is well under way and I have glued on rib 5 to the correct dihedral angle. I listed the tip as per the plan but also made a template to check the fitting that sits on the spar and against the rib itself.

Next task is to lock down rib 5 using spirtlevel for zero bubble. then using my H9 digial incidence meter I will set it for zero degrees reference. The meter will then be placed on the centre line of rib 13 at the tip and will twise the rib LE down so that I have -2 degree washout relative to rib 5. Rib 13 will be locked down and others shimmed to set the washout.

Top spar and then rear spars, sheer webbing go on next. Block balsa for aileron hinge points epoxied on and paper tubes to carry servo wires fitted.

Port panel will then be constructed in the same way.

I have a 3 day weekend coming up, ANZAC day long weekend so hoping to get a fair bit completed.

Photos to show progress.
thanks

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Old 04-23-2016, 01:51 AM
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Bit more progress today in between other jobs.

Locked wingtip in at -2 degrees washout. Main spars completed and sheer webbing done. Rear spars on and will do sheer webbing after flying tomorrow.

All fiddly work that takes a lot of time to get right. No rush and it is satisfying to build as well as relaxing

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Old 04-25-2016, 11:02 AM
  #5
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Finally getting some paint on mine. Another day to put on the lettering and insignias.
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Old 04-25-2016, 01:06 PM
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That looks nice. What is your projected AUW? What engine?

My Fuz is still intact so at least nothing to do on that expect for a new prop. I'm hoping to get onto sheeting the wing over the new couple of weeks. Lots of time spent on it this weekend as it was a long weekend here for ANZAC day.

Starboard outer wing panel is built, added in a small stringer top spar over the 1/2 x 1/4 subspar. Added sheer webbing to that as well. Installed blocks for the hinges and bottom 1/2 x 1/4 balsa doublers where the flap hinges will be.

Port outer wing panel is largely done too, main spar is in and sheer webbed, rear spar done and sheer webbed. Have added the lead edge 1/4 x 1/4. -2 degrees washout has been built in.

Will do the subspar mod and add on the hinge blocks during the week. Will give the lot a sand to ger ribs even in preperation for sheeting.

Need to build in the aileron servos mounts too, will scavenge those out of my old wing.

Then onto centre section to remove the material on rib 2 for the wheel well and add the curved well liner.
Landing gear bearers will be next and once I am happy with the fit and how they go into the outer panel they will be epoxied into place and reinforced with hardwood triangle stock. Final trial fit of the panels to the centre section then I will sheet all of the top.
thanks
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Old 04-25-2016, 01:11 PM
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I have an Zenoah 445 for it. I am hoping not to add much nose weight as the motor is heavy. I also have the SIerra scale retracts for it. I bought the plane framed up with the gear about a year ago. I am hoping to bring it in at mid 30 lbs. My first one I built way back in 1991 with a Zenoah G62 weight in at 30 lbs. I cheated and extended the nose about an inch so the nose weight was not as much to balance it. Hope to get it done in another 2 weeks. I remember building the wing is a challenge. I also built back in 1994 the 101 inch version. It didn't quite fly as well as the smaller one.
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Old 04-25-2016, 01:23 PM
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30bs? Good luck with that! Mine was 42 lbs started lfe with a G-62, no where near enough power so fitted the Zenoah GT-80 twin which is a perfect engine for it.
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Old 04-25-2016, 01:28 PM
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Lets see if the photos will upload this time.

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Old 05-25-2016, 03:12 PM
  #10
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Started work on the wing again today. Half the time spent thinking about where I was up to before!!

Paper tubes for aileron servo wires fitted.
Balsa blocks for aileron hinges epoxied in place.
Reinforced where the outer flap hinge will go with a piece of 1/2x1/4 balsa stock.

Reinforcing the Wong hold down point with some block balsa. These came out of the old wing :-)





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Old 05-25-2016, 03:12 PM
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Bit more progress. I want to extend the dihedral braces an extra rib bay each side. Can't get the depth id like but will laminate the original brace on the centre. I think it should be ok.

Have also fitt d one of the leading edge sheets. I'll trim and sand that match the rib contour and then can sheet. Other laminations will then be glued on once the wing is sheeted.

The one towards the rear will be deeper.

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Old 05-25-2016, 03:16 PM
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Planenutzz:

Got mine done and flying. Thanks for the help with the cowl cut out sizes

Jack

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Old 05-25-2016, 06:56 PM
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no worries
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Old 05-29-2016, 01:24 PM
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Not a lot done this weekend. Spent most of Saturday welding up a bracket to mount the spare tyre to the a-frame on my model trailer.Netflix got the better of me after that and Discovery Wings!!
Sunday did a little bit, first layer of the starboard outer panel leading edge. Scavenged the old servo box out of the port wing and get the fitted in after much fiddling about. Little bit of balsa needed on the top walls then sand back to match rib profile.
Still have the other one to get out yet.
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Old 05-29-2016, 01:25 PM
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Quote:
Originally Posted by jkeze View Post
Planenutzz:

Got mine done and flying. Thanks for the help with the cowl cut out sizes

Jack

good to see it is in Aussie RAN scheme :-)
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Old 05-31-2016, 01:20 PM
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just to show how difficult it is to get the aileron servo box out of the wing and into a new one.Photo shows the old wing. I'll do a cleaner job of getting it out of the wing this time.
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Old 07-21-2016, 06:34 PM
  #17
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Back on the Seafury wing build after being distracted with other matters.

Starboard aileron servo box from the old wing scavenged and needs to be trimmed up a bit prior to fitting into the new wing panel.

Pleased to be scavenging a lot of bits from the old wing as will save a lot of time and effort.

Note on the old wing that the original builder did not fit sheer webbing but I certainly have done!

Stay tuned for more later.


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Old 07-24-2016, 06:28 PM
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stb aileron box now in.

Will do trial fit of landing gear bearers next then install the wheel well liners in centre section.

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Old 11-14-2016, 01:14 PM
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Ok I'm back onto the Seafury wing after a few month waylaid with a female, now that I have gotten rid of her I can get back to serious fun.

Dihedral braces completed, I used the originals as well as doublers. Trial fitted ok. Have started fitted the gear rails but most of that will be done once tthe outer wing panels are on.
Rib centre section remvoed from wheel wells and the currved lined installed and sanded top and bottom to match wing contour.

Will start sanding the wing in readiness for sheeting soon.
Have to install some thin ply in the wheel wells to support the gear doors. Not sure how I am doing that yet.

Outer wing panels and dihedral braces will then be done, gear rails and lastly sheeting.

A few happy snaps.

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Old 11-17-2016, 03:55 PM
  #20
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Thought I would place the main gear dors on to see how it looked :-)

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Old 12-01-2016, 05:38 PM
  #21
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been a bit slow of late. Leading edge laminations to outer panels are done. Centre section and one outer panel sanded ready for joining and sanding. Will sand the other tomorrow. Going to make up a couple of dihedral braces for the LE & TE at the gull join to distribute the loads outwards from the joint in that area.
Once those are made and I have done a trial fit I will epoxy the panels to the centre section and epoxy the dihedral braces in place.
Time to start making the balsa skins too.
cheers
P
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Old 12-04-2016, 01:03 PM
  #22
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Lots of progress over the weekend. Outer panels now epoxied in place. top, bottom and TE dihedral braces epoxied in.

Going to put one through the LE to carry the load in that very weak area. Haven't quite it figured out yet but about 80% worked out.

First photo is the TE 3mm ply dihedral brace.
Second shows it inserted.
cleaned u[p a pile of sawdust on the end of the bench and found a bench sander lurking ubnderneath - funny about that!


It is starting to look like a wing!

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Old 12-11-2016, 02:24 PM
  #23
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I am hoping to have this wing at painting stage by time I have to go back to work. Prorobably have to wait till later in the year to paint it though.
Some happy snaps of progress over the weekend.
Gear rails going in very slowly. Measure 100 times then cut/sand!

Photo of old RAAf Canberra bomber stuck in a park out near Oakey Queensland.


Leading edge dihedral braces in.

Carbon fibre strip laid down on the rear bottom spar. Shaould distribute the loads nicely.

and across the trailing edge gull joint.

Carbon fibre strip along the top of the main spar.

Gear rails going in. This will be a slow process as it has top be spot on. There is a large structural load through this citical section that the gear rails carry. They also get 3/16th ply sheer webbing.



Sunday's planes. FMS 1700mm corsair foamie and 90" Spitfire (G38).
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Old 12-12-2016, 01:02 PM
  #24
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I spent about 3 hours in the shed last night, have the starboard gear rails epoxied in and under clamps. Made some spreaders to keep the rails at the correct 50mm distance from each other.
Will start on the post rails tonight and then do some reinforcement using triangle hard wood stock.

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Old 12-13-2016, 05:36 AM
  #25
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Nice work! I have built a couple of Fury's myself.

JQ
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