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Corsair with DLA 128 4 Cylinder Build

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Corsair with DLA 128 4 Cylinder Build

Old 08-04-2014, 06:47 AM
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flyn2high
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Default Corsair with DLA 128 4 Cylinder Build

This is a build of the Ziroli 93 wing span FG-1D Corsair using their fiberglass fuselage and built up wing and tail. The engine will be the new DLA 128 cc quad cylinder gas engine. It has four 32 cc cylinders with a CNC machined crankcase, 4 FAG German ball bearings and two Walbro carburetors. It comes with two ignition modules and two exhaust stacks. As you probably guessed from my last build (Hellcat Build with 250cc Radial) I love cool engines. The beauty part is that with the optional slanted plug configuration it fits nicely in the stock cowl. With 2 degrees of right thrust and with the plug caps installed there is inch of clearance to the cowl on both sides. The actual width of the engine as I measure it plug cap to plug cap is 9 7/8 wide.



I purchased the engine from Lee at Golden Skies R/C Aircraft, Inc.
The fuselage, canopy, cowl, plans, Robart retracts and wheels were purchased from Mike at Nick Ziroli Plans.
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Old 08-04-2014, 06:48 AM
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I would just like to mention that I welcome any comments, suggestions or questions. Please feel free to chime in at any time.
Old 08-04-2014, 06:52 AM
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The color scheme that I want to do is Marines dream. It has the tri color style of the pacific fighters.

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Old 08-04-2014, 06:55 AM
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The Cowl has a cool nose art that I had to do some work to be able to create a graphic image that would be useable for my model. Here is what I started with.



Then I stretched in in photo shop so that the fasteners were round and the front and rear panel lines were vertical to get a flat perspective.



Then after cleaning up the text I have this which I can use to create a vinyl image, decal or dry transfer image.

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Old 08-04-2014, 06:56 AM
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I started with the stab and elevators. On the plans the elevator arrangement is for a U shaped music wire to join both elevator halves and then use an external horn and clevis to control it. The hinge used is a simple V shaped leading edge on the elevator using flat hinges.

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Old 08-04-2014, 06:57 AM
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I wanted to have the control linkage internal and also have each elevator half controlled by a separate servo for safety in case one should fail in flight. I also wanted to use a more scale like hinge where the leading edge of the elevator was round and fit in a pocket in the stab. I make a sketch on tracing paper over the plans for the elevator hinge.

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Old 08-04-2014, 07:01 AM
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My hinges use 1/16” dia music wire in nylon tubing 1/8” od x .073” id. The tubing is captured in three layers of 1/8” hard balsa sheets and then caped with a radius balsa block. The tubing extends out the end and trimmed flush.

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Old 08-04-2014, 07:02 AM
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I cut up 3/32” G10 fiberglass to use as hinges for the ailerons, elevator and rudder. I will be using three in each. They are 3/8 wide x 1 ” long with a clearance hole for the music wire and a radius on one end.

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Old 08-04-2014, 07:04 AM
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I cut slots in the elevator and stab with my dremel for the hinges. I used a length of 3/16” music wire bent at a right to use with an internal horn. It is sandwiched between two sheets of 1/8” light ply with supporting 3/16” balsa frame work around it. It is on the center line of the nylon tube.

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Last edited by flyn2high; 08-04-2014 at 08:37 AM.
Old 08-04-2014, 07:05 AM
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I fabricated a two elevator horns out of 3/32” G10 and 3/8 dia aluminum rod. These will go internal to the fiberglass fuselage and lock in with a large #10-32 setscrew to the 3/16 elevator shaft.

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Old 08-04-2014, 07:08 AM
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In a similar fashion I made the fin and rudder. I still need to shape the balsa block on the fin.

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Old 08-04-2014, 07:09 AM
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The Ziroli fiberglass fuselage is of high quality and comes with a separate tail section that will be attached later. It is actually easier to work with for now in two halves. I can set the forward section vertical and it will stand up unsupported. As you can see I already cut out for the stab. I will be attaching the stab and fin later and access the control linkage through the retractable tail wheel doors that have not been cut out yet. My first task is to accurately measure where I need to cut the front to accommodate the longer engine.

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Old 08-04-2014, 07:09 AM
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Since the cowl will kind of float without mounting to s surface, I made a sketch showing the cowl position in relation to the fuselage. Since the engine is approximately 9.00” deep the engine mounting surface needs to be 0.85” from the rear datum line. However, my firewall will be two layers of 3/8” aircraft ply and the outer later will be cut out for the engine. This moves the cut line out 3/8” to 1.22”

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Last edited by flyn2high; 08-04-2014 at 07:46 AM.
Old 08-04-2014, 07:11 AM
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I positioned my fuselage leading edge down on my work bench and set it up so that it leaned 2 degrees to the left looking at the top. Using a marking pen in a block of wood set to the correct height I marked the cut line. I cut the nose off using my dremel and a fiberglass cutting wheel.

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Old 08-04-2014, 07:13 AM
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Using the fuselage opening as a template I marked the inside line on my 3/8” outer layer. It is tapered out at 30 degrees. I allowed a little extra and glued both halves together with 45 min epoxy.

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Old 08-04-2014, 07:17 AM
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My plan was to install it from the inside and epoxy it in place. Naturally I discovered that it would not fit through the wing opening. I had to cut a section off and piece it together while it was glued in place. This really did not sacrifice any strength as most of it is one piece and it will get fiberglass cloth and resin on both sides later. To glue the firewall in place I used west system epoxy with low density fairing filler (#407) for added strenght and some colloidal silica (#407) to thicken it. The last photo shows the 2 degrees of right thrust that I will be using.

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Last edited by flyn2high; 08-04-2014 at 07:56 AM.
Old 08-04-2014, 07:20 AM
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With the right thrust the engine mount position should be offset so that the prop shaft comes out at the center of the cowl. I was more concerned with the spark plug cap clearance. I set it up so that the clearance to the closest plug on one side to the other side was equal. It is approximately ” clearance. I needed to offset the engine approximately 1/8” which you can see in the next photo. I used #10-32 blind t-nuts mounted from the rear with a little gorilla glue so they don’t push out too easily.

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Old 08-04-2014, 07:21 AM
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I dry fit the engine and blocked up the cowl to see how it looked.

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Old 08-04-2014, 09:12 AM
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Lou,

Everything looks great so far. I only question your Marines Dream choice. Every ESM Corsair, big or small has the same paint scheme, "Marines Dream" and there are a crap load of them everywhere. I would suggest, seeing how you have fantastic Ziroli Corsair, a clean slate to do what ever you want, pick a paint scheme that no one else has. There are a lot of cool paint schemes from the Pacific, WWII era. I purchased the ESM 50cc Corsair installed the 7-77 radial and it is close to being finished. The first thing I did, I gave it a new paint job and nose art, nothing is more disturbing to me than showing up to a Warbird event and seeing a whole squadron of the same plane.





Just my .02

Dirk
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Old 08-04-2014, 09:46 AM
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as always Lou, I'll be following with interest.

Gunny
Old 08-04-2014, 11:26 AM
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Hi Gunny: I am having a ball doing this but I keep getting interrupted by beautiful flying days.

Hi Dirk: Nice job on your Corsair. I hear what you are saying and I can relate to your post. At least 6 of our club members have the big Top Flight Tarheel Hal including me. At this year’s War Birds over Delaware there were maybe 5 or 6 more. Then at Top Gun last year Andreas Gietz from CARF brings a scale Tarheel Hal complete with a Moki 250. I was thinking the same as you.

That being said I never saw a giant scale Marines Dream at any of the meets I go to. Our club is IMAA legal size only so having a few foamies with the same color scheme is not a deal breaker for me. The truth of the matter is that I really like the scheme. This will probably take me about a year to complete and I want to choose a scheme that can keep my interest up. One other benefit is that the full size is not too far away if I want to pay a visit.
Old 08-04-2014, 02:14 PM
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Lou, great job so far. I like you had to make a choise for my Kit and ARF Corsair. I chose Sky Boss. I did the earlier version and now have the present day on the ARF.
hope to fly it near the end of this month. John Taylor Corsair brotherhood #96, Spitfire Brotherhood #110, Mustang Brotherhood #55
Old 08-04-2014, 03:45 PM
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Originally Posted by flyn2high View Post
The color scheme that I want to do is Marines dream. It has the tri color style of the pacific fighters.

Thank you! I've always loved the Corsair but three tone blue is the only scheme I like on it. I'll be watching this build.
Old 08-04-2014, 04:38 PM
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Yep. it will be a real challenge to paint and a lot of air bush work to get the soft edge but I think it will really be cool. I just finished a Hellcat with similar paint scheme but I think the Corsair is more classy.

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Old 08-04-2014, 04:53 PM
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I've never found it that difficult to paint the tri-color. I've never built an RC model having it though - all my experience is plastic display models. I just start a little bit away from where I want to end up to get my arm motion (the curve) right and use low pressure while working my way to the final line.

Of course everything is simpler when they've already molded in all the surface detail for me.

http://www.airfieldmodels.com/galler...images/002.jpg

http://www.airfieldmodels.com/galler...sair/index.htm

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