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Galeb G2 - new jet made in Serbia

Old 11-29-2012, 12:24 AM
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Default RE: Galeb G2 - new jet made in Serbia

Again, great craftmanship. You make it look so easy. I learn a lot from your buildings.

Freek

Old 11-29-2012, 01:49 AM
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Default RE: Galeb G2 - new jet made in Serbia

Great work!!! nothing beats balsa/plywood model construction!!!

Thanks for sharing every bit of detail.

Regards,
Old 12-04-2012, 12:16 AM
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Default RE: Galeb G2 - new jet made in Serbia

Thank you my friends from Netherlands and Lebanon...

Next steps in my building is to made landing gear doors, ailerons and flaps.

Landing gear doors I made from 1,5 mm thin G 10 plate. First I made templates from cardboard, than from thin aluminum. Thin aluminum was option on my Meister Scale P 47, but for this project I choose G-10. I will offer gear doors like kit part, and doors from this material I can order from firm I take G 10 parts.













For landing gear hinges I use small piano wire...








From my friend's machine workshop I order new shafts for wheels. New one are longer and they also carry middle gear doors.





I must made washer with angle...









For gear doors I made support...






Few evening ago Martin was come and he take measure from some parts from my Panther. He draw parts which we will need soon on Galeb project...





As I told earlier, he is wizard for 3D program...







Martin made all changes on 3D drawings I made during work on the wing...



Servo will open inner gear door, but we need bigger servo arm. Martin draw it...



Many parts you see here will be part, or option parts of the Galeb G2 kit...


Next step was to made ailerons. I have some my system how I made it. First I take 10 mm wide balsa which will be later aileron leading edge.



Than I made angle same like it is on the bottom of the wing, in aileron area...









Next, I made bottom aileron plate. I use 3 mm balsa...



That plate I glue on the balsa of the leading edge...





When glue get dry, I fix that part again on the wing, but made small gap, just a little smaller than will be upper balsa plate...



Other side is higher than it need to be...



...and I sand it down to get same angle like upper wing surface...



Than I take down aileron, and add ribs. Aileron ribs are same I broke from the wing ribs... I use plan to measure positions where ribs must come...







As you can see, I use white (carpenter) glue.

Parallel with ailerons I made servo plates for ailerons. This system I used on all my big warbirds, so this is 100% safe option...







This hard wood parts in which is servo fixed, will be kit pars also...


From G 10 material I made aileron horns for ball links...





On lower aileron side I made hole and trough it I put horn inside. Of course, before that I made straight line between servo arm and horn...
Horn is 20 mm wide in part which come inside of the aileron. Angle is made to get ball link come in same line with aileron hinge... G 10 is 1,5 mm wide and very strong. Horn like this, with two side is unbreakable...
With 5 minute epoxy glue I glued horn in the aileron. I add balsa blocks to made bigger glue area...







Than upper balsa plate...



When glue get dry, upper and lower side look like this...







Next step is to aileron put back on the wing. I use double adhesive tape for that...





On next few pictures you will see that aileron is just a little bigger than wing. That was my goal, so now I just need to sand down that surplus and get perfect transition from wing to aileron...












Linkage will be short and strong...






Same procedure is on the other aileron too...

Regards

Mirce
Old 12-04-2012, 12:24 AM
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Default RE: Galeb G2 - new jet made in Serbia

...
Old 12-05-2012, 12:52 AM
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Yesterday I made fine tuning on ailerons... First I made sanding to get good transition from aileron to the wing...





Next was to made level trailing edge. For this operation I use steel ruler...







After trailing edge, I made leading edge on aileron. Again little sanding...





I put aileron on wing to check how it lying on...







After that I made gutters for hinges... Here is this process step by step...











Same process was made on aileron too... Than I put aileron on the wing, and made fine sanding...



Wherever I out plat with sand paper, transition was perfect...







After cleaning...









Than I put servo and made linkage...









Same process was made on other aileron...







So, ailerons are finished...



Next - flaps...

Regards

Mirce
Old 12-05-2012, 03:12 AM
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Default RE: Galeb G2 - new jet made in Serbia

Looking great mirce, whatever you are doing now with your picture uploads (not as big) it is making it much easier to view the thread.
Old 12-05-2012, 04:03 AM
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Default RE: Galeb G2 - new jet made in Serbia

Very nice work!!Great craftsmanship!!!
Old 12-05-2012, 04:51 AM
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Default RE: Galeb G2 - new jet made in Serbia

Thanks guys...

Xairflyer I wasn't do nothing with my upload pictures. From few days ago, Photobucket have new index page, and linkage are different too (unfortunately more complicated)...
That is reason why I change my mind about posting this topic on English Forum, I need to click now 6 times to add one photo... And you know how much picture I made

Before I go to my workshop to made flaps, look this art photography made by Martin...







Catia is great 3D program, but Martin is even better...

Regards

Mirce
Old 12-05-2012, 06:51 AM
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Default RE: Galeb G2 - new jet made in Serbia

That Balsa framework looks just fantastic a proper model aeroplane.

I thought you had resized them some what, must be loading quicker because not that many pics yet, Page 2 takes for ages now to load. Are you not able to post them on RCU either as expanding thumbnails?
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Old 12-05-2012, 08:10 AM
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Default RE: Galeb G2 - new jet made in Serbia

This is the best thread in a long time Can't wait for more pictures!
Old 12-07-2012, 01:06 PM
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Default RE: Galeb G2 - new jet made in Serbia

Thank you Kimhey... I don't want you wait to long, so here's the continuation of this story...

In last two days I was working on flaps. First few photos of real Galeb G2 on landing with full deployed flaps...





This G2 is from airfield in my town, it's one of five from our aerobatic group "Stars"...
From one of those airplanes i made pictures of flap and wing...









This photos was pretty important when I was working on my flaps. Martin used it also when he was draw 3D project of the wing.
Few more...






On model I made first flap lower balsa plate...







But, most important part was edge between wing and flap, so I start all work on this model part on that point. First I made plate which will come inside of the wing...







Next was to made first of two 10 mm wide balsa leading edge. Same like on aileron, here I use similar technique in building process...





On lower balsa plate I made same angle like angle on the wing and than I glued leading edge on the balsa plate...



Than I underlay thinner balsa plate than it will be upper flaps surface...



...glued side ribs and sand all to get same angle like wing lower surface. I add one more 10 mm wide balsa on leading edge.







When all was sanded I glued lower flaps plate and marked positions for flap ribs...



Next was to put flap construction back on the wing to check alignment...



I glued one G 10 plate. That plate will does not allow the flaps folded under upper flap skin which will come later...








Finally last plate was added. On leading edge I put double side adhesive tape...



I glued back flap on the wing, and sand it until I get nice and smooth transition from flap to wing surface...







On upper side...








Than I take flap down and made final sanding. I made curve on leading edge...

Before:





After:











Now I must made all this steps on the other flap, and made flaps hinges. Hinges will be from G 10 material.


And for the end here is one picture of Galeb G2 in US colors on Oshkosh some years ago...



At 1988 seven G2 was imported in USA. John Travolta have one G2 too...

http://www.airplanezone.com/Oshkosh/...03/page59.html


Regards

Mirce
Old 12-07-2012, 04:16 PM
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Default RE: Galeb G2 - new jet made in Serbia

Thing I love about this plane is all Balsa, Proper model aeroplane !
Old 12-08-2012, 05:00 PM
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...
Old 12-09-2012, 08:25 AM
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Thank you my friend from Ireland...

Yesterday fall first snow... No, snow, snoooooooooooooooowwwwwwwwwwww...











I cleaned snow from house to workshop...



... and pleasure of cleaning around of house I left to my wife...




Ok, now back to Galeb G2...

Yesterday I was working on landing gear cowers. I was looking how to made to smallest cower come in close position. On some my models I used spring or rubber to pull it back.
But here I have a problem, what ever I done it wasn't be good. I don't want to made some big changes on the wing, using offset hinges and more servos for this operation. My goal is to made simple reliable system...

Finally I got idea, and made it like this...







I was happy how I easily solved problem, until moment I got mail from Martin. In mail he asked me am I push landing gear to try how it work with my "brilliant" system? To be honest I wasn't... [&o]

So, back to "lab"...

Looking at what to do, I made new slot which allow landing gear to move freely...









Now it work fine, but middle door was ugly with that big slot. Besides, that slot will be visible on the ground, when model stand on landing gear...
It was 5 AM when I finish that, and I was to tired to made something better.

This morning I got idea how to fix problem. I made new doors, and move screw more in the middle of the aluminum door.
That allowed me to move slot more under that door, and now, in down position, slot is invisible... When gear come up, Galeb will be in the air, so that little slot will be not significant...















That's it for today

Regards from white Novi Sad

Mirce
Old 12-12-2012, 01:04 AM
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Default RE: Galeb G2 - new jet made in Serbia

After i finished work on gear doors, I start with making flaps hinges. Hinges will be made from G 10 material, and the first step was to make drawings of how it should look. After that, drawings were sent to my friend's workshop, who made it.
Every flaps hinge have 4 pieces...









On flap I marked position where hinge will come...



Than with scalpel and thin rasp was made slot for flap hinge part...







Finally flap hinge piece is in position...





But, that piece can't be glued just like that, so I made bigger slot, and on each side add 5 mm wide balsa pieces. Those balsa blocks are glued in the flap, and they connect upper, lower and front flap side.
To get proper slot I push G 10 material, but for now it is just for template...









While the glue dried, I made the hinge parts that go into the wing side... I glued it with 5 minutes epoxy glue.









Back to workshop, and until epoxy dried, I fixed flap, cut down surplus and sand it...





Same procedure I made on servo hinges. On next pictures hinge is same like hinge on ailerons, but later I will change it to get better shape and flap geometry...











Next was to made slots in the wing for flap hinges. Everything is same like on flap. Right now nothing id glued, just set in position...



Then I try how flap work...







Flap can move down even more than they should. Gap for air flow is nice and big. That gap will give more stability on low speed, on landing approach for example...



That's it for now. Today I'll continue work on flaps...

Regards

Mirce
Old 12-12-2012, 06:34 PM
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Default RE: Galeb G2 - new jet made in Serbia

Mirce

All I can say is WOW!!!

What a superb building endeavor, it is so good to see a scratch built project out of wood of this caliber.

I wish I had your time to invest

Thank you for sharing your build, this is like a scratch builders bible!

Keep up the great work, I can't wait to see your completed photos.

I need to start learning 3-D CAD
Old 12-13-2012, 12:11 AM
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Default RE: Galeb G2 - new jet made in Serbia

Thank you Rich on kind words...

Without 3D drawings all this will be almost impossible. Good quality drawings in combination with laser & CNC cut technology is key for so good kit parts.
Flaps hinges are just one example of using technology. Drawings are sent to firm which have CNC router and every part is impeccable.
Using all this raises level of final product.

Other important thing is that here in Serbia we have all machines and technology like wherever in the world, but prices for working hour are much much lower than in USA for example.
So, that gives me ability to use it without not too large cost and at the end I have good product with normal price. That is good for me and great for customer also.

As I wrote here, I have now great team with which I can made all I need for any model. Because that every part of this kit will be on high level of quality, but prices will be very affordable.


Yesterday I was finished work on flap.

First I cut down all balsa surplus on wing around hinges holes and sand it down. Than I put all hinges in places and check is everything aligned as it need to be...



Than I prepare 5 minute epoxy glue and glued all parts. I use German R&G products...





You can see I made new flap control hinge. It have good geometry and flap, in upper position stay very firm without backlash, and on the other hand has more than enough movement...









I hope that today other flap will be finish too. Few more details and wing will be ready for glassing. For that I use R&G epoxy resin and 25 gr glass cloth...

Hope in next few days I'll start working on elevator and rudder, and very soon after that on the fuselage.
Thrust tube and aluminum inlet from Jet Cat arrive to my relatives in Germany, so they will bring me those parts until end of this months.

As can be seen, everything goes in the right direction without complications....

Regards

Mirce
Old 12-13-2012, 03:27 AM
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Default RE: Galeb G2 - new jet made in Serbia

Your flap hinges and horns are very nice, interesting you are using 1.5mm board I have been using 2.4mm for the ones I make, I must try to make some from 1.5mm
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Old 12-13-2012, 03:44 AM
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Default RE: Galeb G2 - new jet made in Serbia

NICE JOB MIRCE.
AMAZING!!!

JOSE
Old 12-13-2012, 09:01 AM
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Default RE: Galeb G2 - new jet made in Serbia

Thank you Jose...

Xairflyer, until now I haven't any problem with 1,5 mm thin G 10 hinges. I guess that you use just one hinge from picture per surface.

Regards

Mirce
Old 12-13-2012, 04:08 PM
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Default RE: Galeb G2 - new jet made in Serbia

I do use the single but also twin like you maybe 1.5mm is enough for twin setup.
Old 12-15-2012, 09:52 AM
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Default RE: Galeb G2 - new jet made in Serbia

Just one small update...

For now Galeb's wing is finished. I still needs to made leading edges, tip tanks and add glass cloth & epoxy resin...

I made right flap on same way like left. To get same angle and position for servo hinge small tool was made...







At the end, few pictures of the wing...











And wing in other pose...







Today I took the drawings of the tip tank in CNC work shop. I hope during next week I'll get tool for tip tank plastic parts.

Martin is almost finished drawings of the elevator and rudder, so that will be next parts on which I'll work.

That all for now folks...

Best regards

Mirce
Old 12-28-2012, 04:19 AM
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In meantime I got tool for wing tip tank.









I add 5 mm balsa for curve which will made plastic on vacuum machine...





Martin was working on his part of the project...







Few days ago tip tank plastic arrived...





Wooden frame fit very well...











And finally, something from last night...











I must again note that this version of the model is not over ...
Plan is to all work on 3D drawings will be finish until middle of the January. Than until end of that month we will make all documentations, plans, so that will be that...

After that Martin and I will start work on our new project, and I must continue work on this model to prepare it for maiden flight in, I hope, May 2013...
Old 12-31-2012, 05:52 AM
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This is definitely last post in this year...

I just want to thanks everyone who follow this topic and call you to continue to read it in next year also. 2013 will be great for this project and I hope full of new sensations about Galeb G2.

For now I want to add few pictures which I get from Martin few minutes ago. Tail is finish, Martin send me file with parts for laser cut, so on first working day in new year we will continue with work on model.









Tail without balsa cover...












Have a nice time tonight and Happy New Year wish you from Serbia

Mirce
Old 12-31-2012, 06:23 AM
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Default RE: Galeb G2 - new jet made in Serbia

Have a great celebration and a happy new year Mirce!

And hopefully we will see the Galeb G2 fly in 2013


Greetings from Norway

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