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Old 04-16-2011 | 10:34 PM
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Timthetoolman1's Avatar
Timthetoolman1
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From: Fort Worth, TX
Default RE: Super Kaos

Sure I can but I don't have any in the assembly stage except the Macchi but it's not my design.
Here's the hinge I cut for the Kaos




Here's another shot with some still on the stick before they have been cut out and trimmed. Use an old blade (because when you're done the blade will be trashed anyway) on a band saw works the best. I keep one old blade around just for cutting G-10.




Here's the one Ed Newman designed for the Macchi 200 (which seems to be parked while I get my pattern fix). In his design he uses a much smaller wire through the yellow plastic inner rod from a Golden Rod. Then it is glued into the wood hing. The thin opaque sheeting above and bellow the wood hinge is .012" G-10 I used to create a cove.




On a wing or stab I design I leave enough material to cut a cove in the trailing edge with a sharpened brass tube the size of the leading edge of the control surface. I then gouge the wood out then wrap sand paper around the brass tube or the LE of the control surface and sand it to the right fit.

For the control surface (let's say an elevator) I leave the front flat and then add a cap strip which I sand round for the LE of the elevator. You will need to cut a trough in the elevator and the cap strip half the height of the carbon fiber tube you will use to run the wire in (the wire runs through the control surface then through the hinge which is attached to the stab). To do this you have to use a router to cut a groove half way into the elevator and half way into the cap strip. The picture shows the 1/8" router bit with a piece of balsa that would be a cap on the front of the elvator.



Once the trough is made you epoxy in a piece of carbon fiber rod (see photo and pretend there is a trough)



Then put some epoxy on the cap strip and glue it all together. Now round off the leading edge.

I'll make a better demo when I do the Dirty Birdy but from here you would locate where you want the hinges, cut the LE of the elevator with the band saw (make it the width of the G-10 hinge so it will slide in) the rod then slides through the tube of the elevator, then through each of the hinges so they dangle. Mark the corresponding hinge locations on the stab, cut the stab (or drill a slot) in the trailing edge. Now use tape on LE of elevator and TE of stab, put epoxy in the TE of the stab where you made the slots, slide the elevator/hinge assembly into the slots, tape it all together and let it dry.