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Brian Taylor Bf109E-4 build

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Old 10-14-2005, 09:42 PM
  #51  
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Default RE: BT Bf109E-4

rich,
i have read of poly u but unfortunately i've not been able to find it around here. guess i'll have to stick with the "classic" methods of finishing. thanks for the info.
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Old 11-03-2005, 08:58 AM
  #52  
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Default RE: BT Bf109E-4

in order to open the bottom rear of the cowl for the exhaust exit i needed to make a new door since i didn't think i could make a fine enough cut to make the cutout piece usable. so i used the monokote trick; clear monokote down and then 5 layers of 5oz cloth and resin.

pic 2: after curing, i traced around the door outline and then popped the glassed piece off and cut out both the door and the opening in the cowl. the door outline was already molded into the cowl so i didn't to retrace the opening from the new door i made.

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Old 11-03-2005, 09:28 PM
  #53  
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Default RE: BT Bf109E-4

pic 1-2: began cutting up the cowl openings. BT recommends enlarging the "oil discharge opening" in the front of the cowl if the engine is to be totally enclosed so i did. Holman provides a second chin section of cowling that can be bolted in place allowing access to the engine (area that is marked in pen). i didn't want to cut any more of the cowl and all i really wanted was access to the glow plug which the front opening gives me so i'm not going that route.

pic 2-5: air intake for the oil cooler. i'm using 1/8" balsa to make intake walls and screen support. sorry for the blurry pic. 1/32" ply piece for the intake guide vane friction fit in place. this needs to be removed to add the screen to the rear balsa piece which needs to be added after painting. i still need to add some microballoons to the front edge where the balsa meets the cowl and feather in.

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Old 11-03-2005, 09:47 PM
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Default RE: BT Bf109E-4

Tibig It is really looking good. The glass work is really nice. Does BT make a little bit bigger short kit for the 109? arround 80 in or so. Did you get the short kit from Bob Holman? Thanks Rich
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Old 11-03-2005, 09:56 PM
  #55  
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Default RE: BT Bf109E-4

rich, i don't think so. i just know of two BT 109 designs, 109F (61"?) and this one 68". Holman did supply my short kit.
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Old 11-04-2005, 06:57 AM
  #56  
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Default RE: BT Bf109E-4

pic 1: to facilitate cooling air to the engine i added some baffles, top and bottom, to the openings in the cowl. this is what they look like from inside the cowl.

pic 2: cowl top. you can just see the muffler extension coming from the crankcase.

pic 3: cowl bottom. the engine sits so far forward that i couldn't get the baffles to direct airflow over the heat fins but more toward the rear of the engine. this is my first time at baffling an engine. i think it will work.

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Old 11-04-2005, 08:32 AM
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Default RE: BT Bf109E-4

Rich,
Platt has one at 79" and Meister has one at 84".

Tubig you are coming along nicely. I have looked at the RCV engines alot. I will be very interested I how it works for you.

Carl
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Old 11-04-2005, 09:31 PM
  #58  
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Default RE: BT Bf109E-4

pic 1: put on the flow coat of West Systems epoxy to the fuselage.

pic 2-3:
while the flow coat is drying i started fooling around with the exhaust stubs. i saw a neat way to do this from Tom Hunt's site on his 109 and thought i would try it. he uses heat shrink tubing around a balsa plug to make the exhausts. unfortunately, as you can from the photo the wall thickness of the pvc heat shrink i used is too thick so i've ordered some polyolefin heat shrink which has thinner wall thickness. so now this will be delayed for a couple of weeks waiting for the heat shrink. looks promising though.


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Old 11-04-2005, 09:39 PM
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Default RE: BT Bf109E-4

Why not just carve One stack from balsa and make a mold? My friend did that on his 109 and they look good. The good part about casting your parts is once you get the part looking exactly the way you want all the rest you cast look just as good.
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Old 11-05-2005, 07:27 PM
  #60  
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Default RE: BT Bf109E-4

bob, i actually have thought of trying to cast them but i think if this method works the stacks will be lighter and look very close to the real thing. plus i won't have to carve out an opening to make them hollow like i would with casing. if this method doesn't work for me then i will cast them.
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Old 11-05-2005, 09:38 PM
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Default RE: BT Bf109E-4

started working the wing. pretty straight forward so far. i laid down 1/4" sq balsa spars, front and rear, and tack glued the ribs on top. then added the top spars. i'm a little surprised with using balsa spars especially on a 68" wingspan but followed BT's plan anyway. as you can see, i didn't glue in rib 1 but will wait until building the second wing half onto the first and then align both ribs 1 for the correct dihedral. i think it's easier this way than try to use a dihedral jig to set each rib separately and then mate them together.
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Old 11-06-2005, 07:58 PM
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Default RE: BT Bf109E-4

finished up the basic wing half construction by adding the rear spar and shear webs to the front and rear main spars. i had to add some balsa scraps to the trailing edge of some of the ribs and then carefully sand to get a straight alignment for the 3/16" sheet trailing edge. BT uses alot of shear webs but the wing is definitely strong, and light.

pic 2 shows how part of the sub leading edge is 1/8" ply which is keyed into the landing gear mount area by gluing to 1/16" ply rib doublers on ribs 2,3,4. now for the sheeting.

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Old 11-06-2005, 11:13 PM
  #63  
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Default RE: BT Bf109E-4

Looks real nice. Nice work.

On the headers, I made these for my 80" span 109F/G from styren plastic and made RTV molds of the left and right header. The parts are made from poly urethane resin.

To get all the stuff you need for this type of molding search Smooth On products.

steve

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Old 11-07-2005, 06:54 AM
  #64  
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Default RE: BT Bf109E-4

wow, steve, those look great!!! you're going to have to tell me how your did the weathering on those suckers! also, does the base of the header show from the outside? (ie. am i going to need to that as well?).
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Old 11-07-2005, 10:02 PM
  #65  
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Default RE: BT Bf109E-4

pic 1: here is what i have for the aileron servo. pretty straight forward. note how it's angled for the proper geometry of the linkage. i will add a paper wire conduit through the ribs later.

pic 2: the flap/radiator bellcrank made out of pc board and using aluminum bushings attached to the ribs via a 1/16" ply plate and 1/4" sq balsa supports. you can also see where i've trial fit the 3/8" sq hardwood retract bearers.
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Old 11-08-2005, 12:08 AM
  #66  
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Default RE: BT Bf109E-4

Tubig your model looks great. I have one of those I'm also working on, and a 109F/G and P-51, and a Hurricane, Zero, DVa, ect..........

Too many at once leads to none getting done.

The header bolt flange will not show much with the cowl closed. I did that because I want to build a static DB605 in one with the cowl open and because I wanted a little extra detail.

The colors on the headers are basically, rust, brown, buff (biege) and black. They are all Tamiya model paints. Air brushed very lightly till it looks like.

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Old 11-08-2005, 06:15 AM
  #67  
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Default RE: BT Bf109E-4

double post.
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Old 11-08-2005, 06:17 AM
  #68  
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Default RE: BT Bf109E-4

the right wing half is mostly done now. still a few odds and ends (namely the retract area) need to be added.
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Old 11-10-2005, 07:14 PM
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Default RE: BT Bf109E-4

here are the flap/radiator bellcranks. i made them out of consecutive sizes of aluminum tube (to the right of the bellcranks - the larger tube being a spacer and the smaller tube being a bushing) and pc board. i still need to drill the holes to accept the pushrod clevises.
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Old 11-10-2005, 07:38 PM
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Default RE: BT Bf109E-4

began work on the flaps and ailerons. since these are fairly small and light BT calls for making them sheeted structures and then simulating ribs using tissue to prevent warping them with shrink covering. also, i went about this a little different since i needed to make a sharp trailing edge and that required beveling the sheeting.

pic 1 - 2: first, i glued the ribs to the leading edge over the plans. then i removed them so i could tack them down and sand the top of the leading edge even with the ribs. i covered the ribs with masking tape to protect them while sanding.

pic 3: then i did the same thing with next piece of 1/4" sheeting along the top angled part of the rib.

pic 4: at that point i added the top 1/16" sheeting. to get the trailing edge to match the bottom sheeting i taped down a piece of sandpaper and, again masking the ribs to protect them, ran the bottom of the flap across the sandpaper to bevel the edge of the sheeting.

pic 5: then i added hinge blocks and the bottom sheeting.

pic 6: i pretty much did the same to the aileron. here they are.

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Old 11-11-2005, 06:16 AM
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Default RE: BT Bf109E-4

you probably already knew this but i forgot to show how the trailing edges come to a point with this method. i had planned to add some 1/64" ply to the trailing edge to stiffen it up but i may forgo this now as i've got the ailerons and flaps how i want them. both sets of ailerons and flaps are completed now. next is hinging.
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Old 11-12-2005, 08:07 AM
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Default RE: BT Bf109E-4

started on the tedious task of hinging the ailerons and flaps. to do this i started by making balsa mock-ups of the hinges to get the positioning and geometry right before cutting up my pc board. after making a balsa template of the aileron hinge/control horn i cut out a recessed area in the aileron with my Proxxon (Dremel) and set the balsa horn in place.

pic 2: then i did the same with the hinge that extends from the wing. i waited to sheet the wing so i could get at the hinging slots with the least amount of trouble but i could only make rough slots as the final length of the slot can't be determined until the wing is sheeted and the ailerons/flaps set in place. to make the rough slots i lined up the aileron hinge with the wing, marked it and used a diamond file to file the slot.

pic 3: i'm not sure if i got lucky or possibly getting better but the end result worked very well. here both hinges for the aileron are trial fitted (again with just balsa mock-ups) using 1.6mm screws and nuts.

pic 4: i felt pretty good about the setup so i went ahead and cut the hinges and control horns from pc board.
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Old 11-13-2005, 07:14 AM
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Default RE: BT Bf109E-4

pic 1: here is the assembled linkage for the aileron and flap hinge/control horn using brass tube as a bushing and 1.6mm machine screw.

pic 2: and then both ends of the aileron. the other end of the flap has it's hinge installed into the radiator side so that will come later. i'm pleased with the way these hinges turned out. they are smooth and slop free. i guess the real test will come when the servo linkage is installed.

pic 3: it looked like i needed to go ahead and join the wings before continuing on with the flap bellcrank linkage and before sheeting so i did that. i transferred the dihedral angle presented on the plans out to the end of the wing and determined that each wingtip needed to be elevated 4 1/4". i cut a couple of blocks to 4 1/4", elevated the wing halves and glued away. both wing halves fit very well together.

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Old 11-13-2005, 01:29 PM
  #74  
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Default RE: BT Bf109E-4

Looking good! Man I just have to have sharp trailing edges.

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Old 12-01-2005, 05:56 AM
  #75  
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Default RE: BT Bf109E-4

back to the wing. added the wing hold down plates to the front and rear of the wing center section. i made some fairly hefty epoxy fairings at all of the joints to ensure strength and i added some triangular stock to the rear of rib 1a where it glues to the the ply dihedral brace for a little more reinforcement.
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