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Construction Pics of a Carden 35% Edge 540

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Construction Pics of a Carden 35% Edge 540

Old 02-09-2003, 06:24 PM
  #26  
rthorne
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Default Construction Pics of a Carden 35% Edge 540

Madmax:

Looks good. I'll use this method for my pull/pull.
Old 02-13-2003, 02:36 AM
  #27  
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Default Construction Pics of a Carden 35% Edge 540

Hello Fellas:

I ended up building my motor box incorrectly (major operator error) as it was not square and would have caused major problems with the remainder of the airplane.

This is my first giant scale build and I learned a few things.

I called Dennis to see about getting some new parts but he suggested heating up the epoxy with my heat gun and prying the parts apart. As usual he was correct and I was able to accomplish this. The only causulaties were the firewall and landing gear plate. The plywood split at the seams. A quick trip to the Balsa USA website and the new plywood was on the way.

I finished rebuilding the motor box this evening and it looks good and square now.

I'll take a couple day break and start sheeting the fuse sides this weekend and then join the fuse sides to the motor box.

Heres a few pics. The first one is the neat new tool my wife bought me for my birthday. Its a Microlux table saw. It was perfect for cutting the new firewall and landing gear plate.
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Old 02-13-2003, 02:37 AM
  #28  
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Default Construction Pics of a Carden 35% Edge 540

And the rebuilt motor box....
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Old 02-13-2003, 05:57 AM
  #29  
wgeffon
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Default Construction Pics of a Carden 35% Edge 540

Rich,

Glad to hear your back on track.
Old 02-14-2003, 09:48 PM
  #30  
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Default Construction Pics of a Carden 35% Edge 540

Thanks Jeff. Looks like the weather won't cooperate this weekend for flying again which is a good thing. I'll be able to spend some time in the shop.
Old 02-14-2003, 09:49 PM
  #31  
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Default Construction Pics of a Carden 35% Edge 540

Madmax:

How do you cut the holes in the balsa sheeting for the wing/stab tubes?

I've never had good luck cutting circles in balsa with an exacto knife without chipping it up.

I see in the instructions that Dennis is suggesting to sharpen the wing tube and use that as a cutting tool.
Old 02-14-2003, 10:37 PM
  #32  
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Default Oh so EZ....

Lets see... I opened the box of wood that Dennis sends along with the kit. Look through the stack of beautiful pre edged balsa, and there it is! a 4X48 with two round holes cut in it.
Slice it in half and there you have your two inner end caps!
On other not so nice kits I just start with a small hole and keep sanding and checking till it's right.

FYI... owner just decided to go with cans on the DA 100. Pics within a couple days will show how to mod the already built front end. More later...

Ron
Old 02-14-2003, 11:16 PM
  #33  
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Default Construction Pics of a Carden 35% Edge 540

..
Old 02-14-2003, 11:31 PM
  #34  
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Default Construction Pics of a Carden 35% Edge 540

Ron:

I just went through all my sheeting and I knew about one 4x48 balsa sheeting which is intended to be the wing root cap. However that is the only piece that has a precut hole.

I will need to cut holes in the fuse sheeting where the wing tube and the stab tube go through the fuse.

So I guess I'm back to my original question, what techniques are used for cutting a good clean hole in balsa. I have a circle cutter which may work, I'll experiment on some scrap.

I'm looking forward to your construction pics of the cans.
Old 02-15-2003, 02:46 AM
  #35  
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Default Construction Pics of a Carden 35% Edge 540

RTHORNE

After you get your sheeting glued together, locate your fuse trusses on the sheeting "UPSIDE DOWN" and hold everything in place. Then use a PHENOLIC tube end (sharpen it), stick it in the hole of the FUSE Socket Support and spin it until it cuts through. AND TAKE YOUR TIME. If you hold everything in place really well, this will work perfectly.
Old 02-21-2003, 12:26 AM
  #36  
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Default Construction Pics of a Carden 35% Edge 540

Hey Madmax:

I was reviewing/studing your web site again getting more ideas. I'm impressed with picture #58. That jig you use does a great job. There does't appear to be any gap between the trailing edge of the wing and the aileron. Nice job.


I think I'm going to have time to work on my plane some more this weekend. I have been experimenting with using my circle cutter for the hole in the balsa fuse for the wing tube. It makes a nice clean cut so it will probably be the way I go.
Old 02-21-2003, 03:06 AM
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Default Construction Pics of a Carden 35% Edge 540

There was a product review of Frank's Hole Cutter in RCM a while ago. It cut beautiful holes in balsa and lite ply. I'll see if I can get more information for you.
Old 02-23-2003, 11:34 PM
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Default Construction Pics of a Carden 35% Edge 540

Captain232:

I used my circle cutter on the wing tube and your method on the stab tube. Your method worked quite well. Thanks for the tip.
Old 02-23-2003, 11:39 PM
  #39  
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Default Construction Pics of a Carden 35% Edge 540

I finally spent some time building today. Yesterday was real nice and we were able to fly. I flew my 330L three times. I spent quite a bit of time on knife edges and vertical lines. I have some set up work to do.

I also had a chance to help out Tommie Weemes. He brought his 1/5 scale HS 123A. Hes in the process of rebuilding it from a crash and installed a new Taures TS-52 engine. It used to have a G62 in it. It was one fine flying plane. You can see a picture of it in the April 2003 issue of Model Airplane News page 24.

Anyways. The fuse is now sheeted and mounted to the motor box. Time to take a break. I'll install the cross bracing during the next few evenings.
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Old 02-23-2003, 11:39 PM
  #40  
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Default Construction Pics of a Carden 35% Edge 540

Another angle
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Old 02-23-2003, 11:40 PM
  #41  
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Default Construction Pics of a Carden 35% Edge 540

Last one for now.
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Old 02-23-2003, 11:48 PM
  #42  
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Default Construction Pics of a Carden 35% Edge 540

Nobody seems to cut the Carden plans.

I always cut plans into sections so its not so cumbersome.
Is there a reason I have never seen anyone do that with these plans?

Rthorne,
How are you holding the plans down to the building surface?
Plane looks great so far.
Old 02-24-2003, 12:26 AM
  #43  
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Default Construction Pics of a Carden 35% Edge 540

Hi Jeff:

I never considered cutting the plans, but it would make it easier. The first thing I did was to take the plans to a local blue print shop and make a copy. That way I'll have one good copy if I need it for any reason.

The fella who built my 330L(GP 33%) cut up the plans. I still have them in the box.
Old 02-24-2003, 12:28 AM
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Default Construction Pics of a Carden 35% Edge 540

Originally posted by rthorne
Hi Jeff:

Its Wayne..........
Old 02-24-2003, 12:35 AM
  #45  
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Default Updates on the EDGE... cans and cowl

The Edge is now ready to cover and a few new changes have been made... first, we are going with cans. What an experience!

Hard to imagine NONE of the 100 manufacturers have posted the correct standoffs, headers and cans for this kit. We have now been through the 2 into 1 from DA and passed 'cause of the midrange "maybe" transition, next, the first set of twin cans that are just a bit too long (without going past the rear motorbox bulkhead) and... two sets of headers, one with too shallow of a drop and the others with the flex pipe attached not even close.

We believe we have it figured out and I'll post more as soon as they are properly installed. What I would like to do is post a proper "drop in" parts list.

Next change, I am going back to the more traditional "cowl ring" design, with the cowl ring now bolting right to F-1. I just can't get a perfect flush (with the hatch and fuse sides) seem with the Carden 1" stand-off design. Have any of you had the same problem?

Finally... following are a couple shots of the cowl template for the new "ring".

And, a EZ change to those awful ply cowl joiners.

First I drop the squares they provide in the scrap box and replace them with a single strip of 1/8"X1/2"X10" birch attached with Pacer Fiber-Poxy. I just can't get regular epoxy to hold all those individual blocks. And YES, I do sand and clean off any release agent. I use "Button HD Socket Screws 6-32X1/2 from Micro Fasteners, (1-800-892-6917) part # SBA0608. 100 count for $4.80 and blind nuts... mounted temporary (backwards) until final fit.

Ron
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Old 02-24-2003, 12:40 AM
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Default Joined cowl...

EZ and works!
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Old 02-24-2003, 12:45 AM
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Default light cardboard cowl ring template...

EZ to copy template, will be 1/4" ply about 1/2" wide except where the 4 8/32 bolts will secure it to F-1. Two on the top from inside the hatch, the other two from the front at the bottom of the cowl...
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Old 02-24-2003, 12:47 AM
  #48  
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Default Template in place before trim to size...

More pics of ply ring secured in cowl will follow...
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Old 02-24-2003, 02:14 AM
  #49  
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Default Construction Pics of a Carden 35% Edge 540

Wow Ron,

You have been busy since my visit.
Old 02-24-2003, 04:24 AM
  #50  
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Default EDGE cowl ring...

Shot shows first stage of ply cowl ring... EZ to do, try it, you'll never go back!
Next will be to mount the ring to the fuse with wax paper in between, fit the cowl and tape, then prepare a slurry of epoxy and c/f and lay in a small bead (unbelievably strong) and finally, trim the ring to shape... will end up 1/2 the size shown.

Ron
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