Another Cuda Build
 

This weekend I am going to begin construction of another Cuda. This one is being built for a friend. I'm going to let my Cuda rest until I get to the same point in the build with this new one, then I will finish them together.
I started this thread as an easy way to keep him informed of the build progress and as always, to let other make comments or suggestions.

It's always a great day when the big brown truck arrives with new toys. Let the fun begin

Steve

RE: Another Cuda Build
 

After doing a parts inventory to make sure everything was in the box I started on the fuse construction.
I think the fuse truss sides along with the motor box are the most critical part of the build. Make sure you get them straight and true and you are a long way to building a good airplane.
I pin a piece of aluminum channel along the top of the fuse truss line and then pin the 3/8 sq. top longeron tight against the channel. This assures a straight truss.

RE: Another Cuda Build
 

looks good , I have one in the barn unbuilt I guess I need to drag it out and get busy. Keep up the pics I might get inspired.

Kent

RE: Another Cuda Build
 

yeah yeah Kent...you said that back in January on the other Cuda build thread :)

c'mon let's get building it !!

RE: Another Cuda Build
 

my problem now is that I finished and am flying my 35 % Cap. This is the plane I have been searching for about 10 years. It fly so well I just cant seem to get excited about any other plane. I guess I'll get back to building soon.

Kent

RE: Another Cuda Build
 

Steve,

You didn't do a Build Thread on your workbench did you? I need one of those :D

Ward

RE: Another Cuda Build
 

the work bench is nothing special. 2x4's for the frame. I did run the edges over a jointer to true them. The top is 2 layers of 3/4" MDF shimmed and leveled in all directions and then a piece of 1/2" drywall for the actual building surface. The back side 2x4 is screwed to the wall with other 2x4 framing built around a stationary Craftsman tool cabinet. I also use a regular 8' folding table. Once the fuse is sitting on it's landing gear I move it over to the table. Makes it easy as I can walk around it and work from both sides.

RE: Another Cuda Build
 

Come on Kent, get it built, I need a new plane to fly. After my first carden all of my other planes are just toys. Lets fill the barn up with Cardens! Ha! Ha!

RE: Another Cuda Build
 

Not much got done over the weekend but I did sheet the fuse sides and started work on the motor box.
As with my first Cuda I did cut the lighting holes is the motor box side and filled the bottom holes with sheet balsa since this Cuda will have a canister also.
Cut the big hole in the motorbox back plate, Drilled the landing gear and gear plate and marked F1 for the DA50 mounting.

RE: Another Cuda Build
 

tonight I started to set up for building the motor box. I get stressed out at this point because you have to check that it is square in about a half million directions and it's always moving around on you.
Anyway, on my Cuda and the one I'm building now, when you try to build the motorbox over the plans, the plans are actually about 3/32" wider than what the motorbox ends up being. It's not really a big deal because the ply for the back of the motorbox and the firewall are the same width so you build it as is and it's just not quite as wide as shown on the plans....it just makes lining everything up while you're trying to build it a little tricky.
This is my third Carden and I haven't found an easy way to build the motorbox yet...6 hands would help.
I thought about getting some 1/4" luan ply and cutting out a rectangle (maybe 2 of them) to the exact outside dimensions of the the finished motorbox and the build the motorbox inside the rectangle....hmmmm.

probably more trouble than it's worth. Guess I'll just do a few dry runs before I mix up the epoxy.


Steve

RE: Another Cuda Build
 

Got the motorbox framed up and epoxied. Lot's of time, lots of patience and lots of clamps.
I'm going to skin the foam before I go any further on the fuse.

Steve

RE: Another Cuda Build
 

today I got the skins glued up. I still edge glue all the skins with yellow glue first. I like using a palm sander on the skins while I can still lay them on flat board. That way there is very little finish sanding to do on them once they are on the foam.

Steve

RE: Another Cuda Build
 

Got the fin/rudder foam sheeted along with the top and bottom decks then I went back to the fuse.
Today I got the cross members and diagonal braces fitted and glued.
take your time. Lots of trial fitting. Your goal nice tight joints but not tight enough to move the fuse sides out of square.
There is no quick way of doing this that I know of.

Steve

RE: Another Cuda Build
 

Steve,

Today we had a chance to maiden the 35% Carden Extra you built last year and all I can say is WOW! :D:D:D Two short 8-minute shake down flights, it flies like it’s on rails, just amazing. It took one click of right aileron (we think because of the cross wind) and that was it, level and straight. You did a fantastic job on this plane; everyone at the field just loved it! It’s a Carden thru and thru, again thanks a million.

This morning at 8:30 AM, my wife and I are down in the basement, checking the CG by holding the plane at the wing tips. Then we verified the CG by putting the Plane on a Kollercraft CG balancer and it was a ¼” behind the recommended point. Then at the field I put it in a 45 degree up line, it had a slight arch back to earth, perfect.

Very little, if any coupling in knife-edge and high rates go beyond my capabilities! In fact, before the second flight I backed down the low rates a bit, it flies very very light. Almost forgot, the canisters and 3-Blade prop, that’s the ticket. Brian was right, what a combo and super quite, I bet it was 94-96 dB max.

Great job and again, thanks. Back to the Cuda thread.

Regards, Ward

RE: Another Cuda Build
 

Ward,

that's great. I'm glad you're happy with it so far and thanks for the kind words.

I would love to see a video of it in the air if you get the chance.


Back to the Cuda. Today I finished some work inside the motorbox and was able to get the bottom deck on.

Steve

RE: Another Cuda Build
 

Hey Ward,

How did the trim scheme look in the air ? Top and bottom visibility etc.

When I came up with it I was thinking the black stripes on the wing would help on vertical up lines but when it was complete I thought that maybe they end up looking too horizontal on a vertical up line.

I'm really stoked that your happy with it. Anyone making that kind of investment is putting a lot of faith in the builder. I appreicate it.

Steve

RE: Another Cuda Build
 

Hey Steve, by the picture above, looks like you've never dropped an Exacto knife on the ground while you were building...;)

RE: Another Cuda Build
 

HA more than once. The dumbest thing I did was try to catch it !! You only make that mistake once.
Normally I wouldn't be in my shop without shoes but on the day I was making the skins I moved all the items into my family so I could watch the NCAA Lacrosse championship while I was working on the skins.

RE: Another Cuda Build
 

Is that the new family room/home theatre you just finished up? Your wife wasn't a little anxious about you playing with glue on the new carpet? By the way, how did Duke do in the finals....???:D:D:D

RE: Another Cuda Build
 

NOOOOOOOO, not the new room....that was the upstairs family room/living room with junk builders grade carpet. Beside, the dog has already done worse to that carpet than Sig Bond can do. I'm still waiting for LazyBoy to deliver the funiture for the new room. I think they are waiting for the right tree to grow to get the wood.

RE: Another Cuda Build
 

Duke was "stripped"of the ball after trying to go in deep and being rejected. They never gave up and scored with a 3 on 1.
however after review they were called for violation.

RE: Another Cuda Build
 

I thought Duke was suspended for the season?

RE: Another Cuda Build
 

boy you just took all the funny out of that....geez

RE: Another Cuda Build
 

Steve,

Trim scheme works :D and yes, up-lines are easy to track. I'll try to get a couple pictures this weekend. And video during the week (mon.-fri.) in two weeks, next week is graduations, high school sports awards, etc... another crazy week.

The month of July will be great, I have three weeks off, in a row:D I'll get around 22 days of Flying the Extra and should have it dialed in by then.

Ward

RE: Another Cuda Build
 

Pretty decent progress on the Cuda today.
Got the bottom deck rough sanded and the tail gear mount installed. Then went back to finish up the motorbox.
the bottom 1/4" to fill in behind the landing gear. and the balsa sheet to make the tunnel for the canister.
Also drilled a 1 1/2" hole in the firewall since the carb on the DA50 ends up really close to the firewall so this hole gives
a little more space of air intake. Problem is the top of the canister tunnel goes right right across the middle of this hole so I needed
to close the top half to seal off the off the top half of the motorbox.


Steve