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Ultra Sport 60 build,

Old 04-22-2009, 05:43 AM
  #176  
MinnFlyer
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Default RE: Ultra Sport 60 build

Don't worry about that gap yet.

Give me some time and I'll draw some diagrams about it
Old 04-22-2009, 07:33 AM
  #177  
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Default RE: Ultra Sport 60 build

When it comes time to ass the fillets, lay the fillet former against the wing and glue it to the fuse sides front and rear. Note in the manual how you should bend the rear side level for a nice look.

Also make sure you have waxed paper between the fuse and wing before you start.

With the fillet in place, glue a strip of 1/4" tri-stock between the rearmost 1/3 of the fillet former and fuse (If you go any further forward it will interfere with the surface of the filler and make sanding more difficult)

Now glue the fillet base to the rest of the fuse with 1/8" square stock or small scraps. Remember to keep them small so they don't protrude through (what will become) the surface of the wood filler.

You can even use a few short scraps and fill gaps with epoxy, or thick CA and kicker.
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Old 04-22-2009, 10:19 AM
  #178  
vmsguy
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Default RE: Ultra Sport 60 build

Do what Mike says... his is the best solution.

I'd only add, that if the gap between the wing and fuse is good sized, and you're not getting a lot of contact area between the 1/8" square stock and the fuse, I'd use some 1/16" scraps to fill the gap a little first. Glue them to the bottom of the fuse. Build up the fuse a little.

This will give your more surface area for the glue to attach when putting on the 1/8" square stock in place.
Old 04-22-2009, 12:22 PM
  #179  
Alex7403
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Default RE: Ultra Sport 60 build

Thanks Mike, i'm studying it now and i'll do that when i'll get there these sort of things i need to plan ahead.

meanwhile i'm doing the turtle deck.

Alex

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Old 04-22-2009, 01:36 PM
  #180  
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Default RE: Ultra Sport 60 build

Alex,
Do you have a razor plane?? [link]http://www3.towerhobbies.com/cgi-bin/wti0001p?&I=LXAA64&P=ML[/link] . This as easily got to be one of my most favorite tools in my box for building planes. It makes very quick work of shaping large pieces of balsa like the Ultra Sport turtle deck, wing tips, and the cowl area. I've tried the power plane from Hobbico but I like this tool better. With this in the palm of my hand I feel I have a lot more control over what I'm shaving off. On my last Ultra Sport it only took me about 5 minutes to shape the wing tips and cowl using this. I like them so much I actually have 3 of them laying around my shop!!!

Ken
Old 04-22-2009, 02:22 PM
  #181  
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Default RE: Ultra Sport 60 build

Concure with Ken's recommendation of a razor plane. Very, very handy.

I also find a half-round metal file (with a reasonably agressize teeth pattern) very handy as well. Very good at taking away extra balsa stock. Like if you cut a servo mount hole, and it's a bit tight.. the file will clean it up nicely and quickly.

And looking at the posted picture. You already know the "you can't have too many clamps" rule.
Old 04-22-2009, 02:44 PM
  #182  
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Default RE: Ultra Sport 60 build

yes i got the razor plane for this task tried it now and i like it.

yes i have drawer full of clamps and i still miss some...

no you cannot have too many clamps.
Old 04-27-2009, 09:53 AM
  #183  
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Default RE: Ultra Sport 60 build

Funny, I was just looking for something in my Ultra Sport build thread and came across some pictures of that exact same gap you referred to earlier:

http://www.rcuniverse.com/forum/fb.asp?m=8045740

And here are some pics of covering the fillet:

http://www.rcuniverse.com/forum/fb.asp?m=8342677
Old 04-27-2009, 10:20 AM
  #184  
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Default RE: Ultra Sport 60 build

Mike,

Have you ever had success on these fillets using monokote? I assume I would use the same method, but with more heat and a thicker glove?

Ultra coat is understandably easier, but I personally don't like using ultracoat.

Brian
Old 04-27-2009, 10:22 AM
  #185  
MinnFlyer
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Default RE: Ultra Sport 60 build

Hi Brian, I did the GP Mustang 40 fillets (Identical to the US) with MonoKote the same way and it worked just great.
Old 04-27-2009, 10:24 AM
  #186  
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Default RE: Ultra Sport 60 build

All of my Ultra Sports were done with Monokote and I was able to do the wing filet on them with no problems

Ken
Old 04-27-2009, 10:52 AM
  #187  
XTOL
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Default RE: Ultra Sport 60 build

I took the easy way out on the fillets on my scratch built US60...
I painted them. I used Lustrekote and it matched up with the
Monokote used on the fuse very well...
Old 04-27-2009, 10:56 AM
  #188  
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Default RE: Ultra Sport 60 build

I don't use a razor plane, but this one from Stanley Tools:

http://www.stanleytools.com/default....Trimming+Plane

The great thing about it is that you can resharpen the blade and have good adjustment on how much blade is exposed. A razor plane doesn't have the blade adjustment.
Old 04-27-2009, 11:28 AM
  #189  
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Default RE: Ultra Sport 60 build


ORIGINAL: Bax

The great thing about it is that you can resharpen the blade and have good adjustment on how much blade is exposed. A razor plane doesn't have the blade adjustment.
Bill,
THe razor plane from Master Airscrew does have and adjustment on the blade so that you can adjust how much blade is used on the cut.

Ken
Old 04-27-2009, 05:31 PM
  #190  
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Default RE: Ultra Sport 60 build

well I got too enthusiastic with the razor plane and at some points I shaved off too much, got to be more careful with that tool.
i'm planning to seal that with wood filler and make it round with a strip of sanding paper at the final sanding.

Alex
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Old 04-27-2009, 06:54 PM
  #191  
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Default RE: Ultra Sport 60 build

I’m at the spinner ring thing.

I see that I’ll have to sand the chin and top front balsa blocks to fit the motor distance.
I didn’t drill the holes for the motor in the motor mount yet.

Question:
With OS 75 AX and a nose gear configuration in mind, do I prefer to put the motor to the front or to put it towards the rear on the motor mount CG wise and ease of access?
I’m not religious about a tight gap between the spinner and the spinner ring it can be 1/4” or more.

Thanks
Alex
Old 04-27-2009, 07:27 PM
  #192  
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Default RE: Ultra Sport 60 build

Alex,
On the area that you shaved too much wood away from, glue some 1/16" sheet into the area and resand it to shape.

On the engine. If I remember correctly the plans call for a specific distance from the firewall to the back of the spinner plate. And then you build the cowl to that distance. If you have to move the engine out a bit to accomodate the size just make the cowl a bit longer to fill that extra space. While many don't worry too much about the gap between the cowl and spinner I'm not one of those. Personally I like for that gap to be as tight as I can get it, 1/16"-1/8" gap. When you are building the cowl like you do for the US it's easy to get a good tight gap. Just build the cowl as specified in the instructions and you'll be fine.

Ken
Old 04-27-2009, 09:29 PM
  #193  
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Default RE: Ultra Sport 60 build

You don't want a big gap there. If you do, you'll need to move the engine back an extra 1/4" anytime you need to remove it and you don't have a lot of space to play with.

Stick to doing it exactly as the manual tells you to.
Old 04-27-2009, 09:37 PM
  #194  
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Default RE: Ultra Sport 60 build

Thanks Ken, thanks Mike i'll stick to the plan.
now i used 1/32 spacers between the spinner plate and the ring as the manual suggested.

Alex
Old 04-27-2009, 10:36 PM
  #195  
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Default RE: Ultra Sport 60 build

The fillets really add to the plane's looks. I used brown balsa filler and a couple of spoons to shape them. They are pretty easy to cover with monokote.
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Old 04-28-2009, 12:11 AM
  #196  
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Default RE: Ultra Sport 60 build

I think I see a new pilot in the future........ [sm=shades_smile.gif]
Old 04-28-2009, 12:49 AM
  #197  
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Default RE: Ultra Sport 60 build

Questions:
I have ¼“ missing from both sides top and chin balsa blocks, should I add ¼“ strip to every side or there is a better idea?
I don’t know how it happened and it doesn’t matter, probably didnt sand the firewall sides.

Thanks
Alex
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Old 04-28-2009, 06:40 AM
  #198  
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Default RE: Ultra Sport 60 build

Wow, that's really weird. Maybe you put the firewall in sideways? (I don't remember if it's square or not)

In any case, no biggie, yea, just add a strip of wood to each side and sand it down in the shaping process
Old 04-28-2009, 10:37 AM
  #199  
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Default RE: Ultra Sport 60 build

alex: The forward ends of my fuse sides were also wider than the upper and lower blocks, similar to yours, and I thought I followed the plans pretty close. I assumed the situation was an accomodation to the variation in the length of the 2-S and 4-S firewall spacers. After the blocks were glued in place, I just shaved the ends of the fuse sides to match the shapes of the blocks. Another use for the razor plane.

wuness
Old 04-28-2009, 09:58 PM
  #200  
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Default RE: Ultra Sport 60 build

I just finished that cowl block project. I have the 2 cycle blocks. I am using an OS75AX which I have installed tight against the motor mount bolts. All my blocks fit fine. I have it planed, sanded and have worked the nose area so it conforms real well to the True-Turn 2 3/4' spinner. I installed a 2/56 blind nut in the center of the wing and on the recomended CG. I pieced everything together as best I could at this point. It looks like the 6 volt battery pack will need to go back near the servos. My lateral balance is done and the wing opposite the cylinder needed 1 oz. of lead. I glued that to the rib that the tip is glued to. I used JB weld and cleaned the lead well. Now I can finish covering that wing. I do that a crazy way. I cover the whole wing except the top on the side where the lead will go. I do cut out those pieces of Ultrakote and tape them to that wing when doing the lateral balance. This US 60 should be ready to go in a week or so. Our field is still a wet mess though.

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