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Jr Falcon Build

Old 12-18-2011, 12:06 PM
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Rubbernecker
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Default Jr Falcon Build

As promised, here is the starting of the Jr Falcon build. Started last week, but took pictures as I progressed. All parts were cut out with hobby laser. Plans were provided by Gene. I tried a different process (not sure I like it on this size model) of laminating the leading edge so that a 1/16 balsa could be layed up in the middle to create a tab and notches were put in the ribs. I have a hard time centering leading edges up on ribs????? It worked o.k., but it feels heavy and very time consuming. I also made the webbing with slots and it just inserted over the slots in the ribs. Again, very time consuming (to draw) and not sure it's not going to leave a little gap at each rib. Will see what it looks like when it's covered. First pictures are of stab.

John
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Old 12-18-2011, 12:12 PM
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Rubbernecker
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Default RE: Jr Falcon Build

Next is the making of the laminated leading edge and assembly of the wing. In the background of picture 4, you can see the laminated leading edge as well as the slotted webbing. Gee, building with magnets is great. I was scared to get rid of my old building board (hollow core door with ceiling tile) but someone here advised I wouldn't look back and I haven't.

John
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Old 12-18-2011, 12:16 PM
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Rubbernecker
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Default RE: Jr Falcon Build

Here are the fuse parts cut out ready to be joined (typical Goldberg style). Need to do it like this because my laser will only cut 14 1/2 inches long. Will join them today and shape the wing leading edges while they dry.

John
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Old 12-18-2011, 04:31 PM
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Default RE: Jr Falcon Build

It's water under the bridge for you now, but I think the laminated leading edge technique doesn't add much - other than weight.
Notched leading and trailing edges do make for easy jigging and straight building though.
I think the best strength/weight/jigging compromise would be to cut shallow notches about 1/32" deep in solid stock, and make substantial glue fillets.
Old 12-18-2011, 06:33 PM
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Default RE: Jr Falcon Build

Yea, it wasn't about strength on the laminated leading edge, it was about an alignement tab. Need to come up with a different tech. May work well on a larger model. Cutting grooves/notches in solid stock (leading & trailing edge) for the ribs to slide in is pretty difficult and my table saw blade is wider than the 1/16 inch ribs.

John
Old 12-18-2011, 10:54 PM
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Default RE: Jr Falcon Build

Looking good rubbernecker, I recall recently passing up on this model just because it is so much bigger than what i am currently flying.

Keep us up to date on progress plz
Old 12-19-2011, 02:59 AM
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Default RE: Jr Falcon Build

Following your build. Where did you get the lazer cut parts? I had to cut mine by hand after down loading the plans from Dave Fritzke's site. Would like to build both the Falcon 56 & Sr Falcon someday. Heres a pic of me & my Jr Falcon @ this years VRCS meet in NC......Gene
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Old 12-19-2011, 05:18 AM
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Default RE: Jr Falcon Build

It's my own laser. I gave up trying to hand cut stuff. Never could get ribs & notches consistent. Have made numerous 1/2 A and smaller stuff (Pageboy, Hummer, Baby Flite Streak etc.) Just about fininshed shaping the leading edge on the wing panels. Need to do the tips. Have also finished installing doublers and center bulkheads (the 90 degree ones). Noticed I hadn't cut a firewall so that was the holdup on joining the fuse halves. My bride wanted to go look at Christmas lights last night so I didn't make much progress. I think we are going again tonight. Ugggggggg! O'well, need to keep her happy. May do a Jr Skylark after this since it is the same wing and tail.

John
Old 12-19-2011, 09:22 AM
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Default RE: Jr Falcon Build

WoW! Thats really neat, being able to use your own lazer. Hope you have as much fun flying your Jr Falcon as i do mine. I been working on a Skylark 56 twin for the last two years off & on myself. All Carl Goldbergs planes fly well...Gene
Old 12-19-2011, 07:55 PM
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Default RE: Jr Falcon Build

Things progressed nicely tonight, I didn't have to go look at Xmas lights. Was going back and forth to the TV to watch my Steelers play. I got the vertical fin and rudder cut out as well as firewall & LG blocks. Holes were drilled in firewall and blind nuts installed as well as LG mount holes for sewing the gear in place. The alignment was time consuming, but will pay off in the long run. Here is the fuse using the magnet jigs and a shot of it assembled. Hopefully tomorrow night I will get the wing halves joined and start sheeting on the fuse top and bottom.

John
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Old 12-20-2011, 02:11 AM
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Default RE: Jr Falcon Build


Looking good! Nice clean work....Gene
Old 12-20-2011, 04:17 AM
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Default RE: Jr Falcon Build

Thanks!

John
Old 12-20-2011, 07:15 AM
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Default RE: Jr Falcon Build

Yes, Very nice looking build. I like your laser cut parts, too.
Old 12-21-2011, 03:31 PM
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John Cole
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Default RE: Jr Falcon Build

John,
Really nice work. I like the updated laser approach you are taking.

Here are pictures of mine built from the kit. It came in at 16.2 oz RTF. The glide is really nice, that airfoil seems like a good one. I added elevator control, too chicken to try it rudder only like my early one.

John
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Old 12-21-2011, 04:52 PM
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Default RE: Jr Falcon Build

Nice work guys, a little envious here;I will stick to building the "stick" style planes and the simple builds.
Old 12-21-2011, 07:04 PM
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ORIGINAL: John Cole

John,
Really nice work. I like the updated laser approach you are taking.

Here are pictures of mine built from the kit. It came in at 16.2 oz RTF. The glide is really nice, that airfoil seems like a good one. I added elevator control, too chicken to try it rudder only like my early one.

John
Nice plane. I'm going elevator on mine as well. My first attempts 30 + years ago were with pulse rudder only and I was not successful. Like Jaspur, I'm envious as well. My construction is no where good enough for transparent covering. I have learned that a good painter makes a carpenter look excellent. Hopefully will have some updates tomorrow.

John
Old 12-22-2011, 09:14 PM
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Default RE: Jr Falcon Build

O.K., tonight's update does not include pictures. Everything is clamped, blocked or weighted. I shaped the wing tips and joined the two halves. Installed nose gear and sheeted some of the fuse. Need to leave some off so I can get the push rods in. Also glued vertical stab into horizontal one and drilled holes for hinges in rudder. Will use figure 8 method. Very free for a 1/2 A. I will take a couple of pictures tomorrow. Can't decide if I want to use rubber bands or bolts.

John
Old 12-23-2011, 08:27 PM
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Lot's of progress over the last couple of days. All the sheeting and rough sanding on fuse is done. Elevator done and rudder needs to be attached. Landing gear installed. Pushrods done. Stab needs to mounted and aligned. Wing needs to be glassed and aligned. Opted for rubberband hold down for wing. Think i'm going to cover stab in silk, wing in poly span and fuse in silk span. Never used the poly span before and hear it doesn't like tight curves, hence using silk on stab. If Xmas doesn't get in the way, may start covering tomorrow. Needs a couple of coats of dope first and the Little Lady does not like me to smell the house up. [&o] First picture was before sanding and the other 2 are sanded and the elevator being assembled. Stay tuned.

John
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Old 12-23-2011, 09:17 PM
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Default RE: Jr Falcon Build

There's nothing wrong with that!
Old 12-24-2011, 03:29 AM
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Default RE: Jr Falcon Build

Rubberneck, I used rubberbands on the wing on mine & glued the stab in place. The rubberbands are very forgiveing on those not so perfect hand launches, hence im glad for them!
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Old 12-24-2011, 07:27 AM
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ORIGINAL: gene6029

Rubberneck, I used rubberbands on the wing on mine & glued the stab in place. The rubberbands are very forgiveing on those not so perfect hand launches, hence im glad for them!
Yea, I opted for the easy way out. I also plan on glueing on the stab. Never liked the idea of rubberbanding that. Great shot of you launching. Mine have been know to be at a 45 degree angle laterial after launch and then it was discovered that the control throws are too much and if she survives, the next minute or so is torment............. [X(] I figured by doing a build online, I would stick with it. I have a Hummer ready for paint as well as a Baby Flight Streak, so I have no problem jumping around. Thanks for all the kind words guys.

John
Old 12-24-2011, 08:45 AM
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Default RE: Jr Falcon Build

Yea, your a brave sole building online! I did it once with a Buzzard Bombshell. Atleast your build looks really neat & clean. I'm gathering up materials to start my Mini Mambo. Too bad we dont live closer, would be fun flying this 1/2a stuff together I try and fly my stuff early in the mornings before the peanut gallery arrives. Keep up the nice work...Gene
Old 12-24-2011, 10:23 AM
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I'm kinda the lone wolf at my club with 1/2 A. Wish we had some others that flew them. They're pretty economical. I had some ukies out there this summer and you should have seen all those grown men laughing. I have a buddy that I built a Stunt Chimp (copy cat of Stunt Man) for and he flew uc for the first time. He is a very good rc pilot with fixed wing and helo's. Well, after I flew it and some others, I told him it was his turn. Fueled it up and let it run to burn some off and I launched. He was doing pretty good till he started getting dizzy. I was rolling around on the ground laughing. Finally he went down and I'm crying telling him he cannot fly from the ground. He was on his knees going around. I would have paid a million bucks to have it on video. I couldn't have shot it because I was laughing too hard. Anyway, he finally made it back to his feet and she ran out of fuel. Stuffed it a few times and then it broke. Ca'ed it back together and was back in the air. Had him doing loops before we were done. What a hoot. My side hurt for a week after that. I have the plans to the Mini Mambo that I plan on putting in cad so I can cut kits. I already have the plans to Bob Harris's Micro Mambo (he sent them to me) in cad and a cut file, just haven't found time to build it. Got the stab glued on the Jr Falcon and glassed the wing. Bottom side only. Won't be doing any outside maneuvers. Merry Christmas.

John
Old 12-24-2011, 11:06 AM
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Default RE: Jr Falcon Build

Good stuff!

Some day play around with the Polyspan. I've gotten it around compound curves very well by pulling on it while I apply the heat. Just fool with it awhile and I'm sure you'll get the hang of it. Best material out there for painting and staying light but strong.

Jim
Old 12-25-2011, 06:17 AM
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Merry Christmas! Will be a litle delayed for us, my Bride had to work today, she is a nurse. The kids decided they wanted to wait till mom got home before opening any presents or seeing what Santa brought. Very thoughtful considering they are teenagers. Well, I discovered last night even with all the years of building, I made a boo boo on the Falcon. The stab sheeting at the leading edge is not as wide as the surface it was mounted to. The problem that creates is there is nothing to attach the covering to in the leading edge area. [] Guess I will be putting some strips in there. If I had've built it as per instructions, I wouldn't be having this problem. I just hate the idea of holding the stab on with rubberbands. Not real keen on using them for the wing.

John
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