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ULTRA Ultra-Flash

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ULTRA Ultra-Flash

Old 04-10-2013, 02:02 PM
  #1  
mitchilito
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Default ULTRA Ultra-Flash

Last flying season I banged up my Classic Flash. As is usually the case there were two or three causative factors. Bottom line: I attempted a takeoff with the brakes on!![&o], hit the tall grass at the end of our runway and cartwheeled. The wing was thrashed, the vertical stab folded/destroyed and some nose stress cracks etc. I wasn't real happy but when the dust settled I decided to go ahead and repair/upgrade to the Ultra Flash configuration. The ultra conversion itself is kind of a pain but I would also have to repair the fuselage and remanufacture a new vertical stab!

Well, I just finished it a few days ago and decided to post the pics I took along the way. Some of you might find it interesting. For starters I'll include the pics of the Classic just as I flew if for all of last season. The Classic Flash is a FINE jet but I'll go on record right here and say I always HATED the way it acted in the pattern with anything more than minimal flaps. Very vague in pitch to the point that I quit using more than take off flaps for all ops unless I really really had to have more. IMHO the addition of crow is the only thing that made slow flight tolerable. Other than that I really loved my classic and was very shocked/dismayed when I basically destroyed it! (it had 170 flights on it at time of impact).

Look closely at the wreck and you'll see the smashed canopy in the foreground. Can you believe the frame itself was perfectly fine! The bubble on the other hand, not so much. . .
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Old 04-15-2013, 12:55 PM
  #2  
mitchilito
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Default RE: ULTRA Ultra-Flash

Here's a picture after post-crash tear down/evaluation. If you look close you can see significant cracks on the nose. Final tally: wing totaled, vertical stab totaled, nose gear damaged, canopy destroyed. Fuselage was in fair shape expect for the nose cracks. All on board equipment unharmed.
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Old 04-15-2013, 01:12 PM
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mitchilito
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Default RE: ULTRA Ultra-Flash

First order of business was to strip paint off the fuse and repair the nose cracks. Backed up all cracking with 6oz cloth. A tiny little bit of bondo later problem solved. I thought long and hard about how fix the Vstab. Finally decided to completely remove it right down to the fuselage - leaving an enormous hole. I then filled the hole with high density blue foam and sanded to fuselage contour as if there never was a Vstab at all. I then covered the whole area with sticky release film and laid up a mold over it. Once the mold cured I busted out the blue foam.

Here's a picture of the finished mold (laying upside down beside the fuselage) and the foam plug already broken out. Also a pic of the mold in place as it would be when used it to do a lay up from the inside of the fuselage to close up the hole. When the layup was done and the mold removed it was just as if the Vstab had never existed!
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Old 04-15-2013, 01:50 PM
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Default RE: ULTRA Ultra-Flash

Sorry to hear about your classic, but glad it will fly again! How did you remove the paint?
Old 04-16-2013, 04:12 AM
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mitchilito
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Default RE: ULTRA Ultra-Flash

I wet sanded as much as possible without exposing bare glass to avoid exposing pin holes.

I settled on using high density blue foam/balsa/.75 glass cloth covered structure for the Vstab. I used a feathercut machine to cut the core - the most challenging one to date due to the extreme sweep/short span. I was amazed to get it right first try. In the pics you can see where I cut the core for the main spar and also the servo mount. I located the main spar to coincide with the carbon bulkhead in the fuselage and used an aluminum bracket to ultimately join them. If I had it to do over again I would use 1/64 ply sheeting. Balsa/glass dents pretty easily.

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Old 04-17-2013, 03:59 PM
  #6  
mitchilito
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Default RE: ULTRA Ultra-Flash

I did a vacuum bag layup to install two layers of 3.5oz kevlar on the left outside hingline surface to create the live hinge. In the picture you can see the right side gap seal sitting on top of the stab. It's the dark rectangle.
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Old 04-17-2013, 06:13 PM
  #7  
RC Larry-RCU
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Default RE: ULTRA Ultra-Flash

Mitch. Looks like youre did an awesome job of getting that beautiful bird back in the air. If Im correct on this, you'll be sporting a new style wing as well? We certainly hope to see it knocking holes in the sky at NC's "First In Flight" Jet Rally again this year.
Oh by the way,,,,, I was in the Jackie Sacks Wing Bag factory tonight. Ya get one guess who's new wing bag is on the table getting fab'ed!
Old 04-18-2013, 11:51 AM
  #8  
mitchilito
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Default RE: ULTRA Ultra-Flash

Yep, it's an Ultra flash now and it will be burning up the skies at FIF. I've had my hotel reservations for a couple weeks now. I am really looking forward to your awesome event! I'll bet it's gonna be HUGE this year. And I can't wait to get my new Jackie Sac!
Old 04-18-2013, 12:52 PM
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Default RE: ULTRA Ultra-Flash

I applied 3/4oz cloth to the balsa covered fin and it was time to install. I removed the first 1/2 inch of foam from the bottom inside to receive 3.5oz cloth from the inside of the fuselage to seal the fin in place. As mentioned before I used an aluminum bracket to join the Vstab to the original bulkhead with 4 4-40 bolts. It ain't going anywhere EVER. I built up some nice fillets and then it was time to paint.

Last pic: the new wing and stab showed up just in time for airframe completion
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Old 04-18-2013, 01:03 PM
  #10  
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Default RE: ULTRA Ultra-Flash

I liked how the new fin looks.. Nicest Flash ever?
Old 04-18-2013, 02:13 PM
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Default RE: ULTRA Ultra-Flash

looking good Mitch, maybe have to send it out west to do some hill climbing with Da boys. I am sure you got a box it will fit in.

Kevin
Old 04-18-2013, 03:49 PM
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mitchilito
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Default RE: ULTRA Ultra-Flash


ORIGINAL: seflyer

looking good Mitch, maybe have to send it out west to do some hill climbing with Da boys. I am sure you got a box it will fit in.

Kevin

Har Har Har! Yep, I still got the box you sent to me in, Kevin. That crate is a piece of furniture. Sadly, I seriously doubt the new Ultra-ultra will ever go back in it
Old 04-18-2013, 03:58 PM
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Default RE: ULTRA Ultra-Flash


ORIGINAL: erbroens

I liked how the new fin looks.. Nicest Flash ever?
I like the original Flash Vstab just fine. It is in keeping with the overall style of the jet which to me looks a lot like an AirForce T38 - just "fattened up" a little and the stock stab is right off the T38. However, I always wished it had the more swept "bandit" style Vstab. When I broke the original stab off I had the chance to make it happen. Now to look at it I could not be happier. I really think it is a big improvement but I realize it's all a matter of taste. It seems to match the more swept Ultra lines better.
Old 04-19-2013, 04:33 PM
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mitchilito
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Default RE: ULTRA Ultra-Flash

I'll go on record right here and say that I knew basically bupkiss about painting when I dove into this project. I decided to use the best paint I could get locally: PPG two part automotive urathane acrylic. Primer through basic white was pretty straight forward but then it came time to apply that awesome T-bird scheme and the fun began! In a nutshell I tried a number of layout techniques to duplicate the original scheme, none of which worked. I finally hit upon a process that would faithfully duplicate this, or any other, scheme properly. First I applied self sticking plastic wrap to the area to be laid out. Using sharpie marker you can layout the scheme and erase/correct until it's perfect. Once satisfied it's peeled off and the scheme transferred to mylar templates. Once the mylar is trimmed to the layout you can tape it to the aircraft and use a fine line sharpie to transfer the lines to the aircraft. These lines are used to apply your vinyl mask. For the sharp radius required for this scheme I used very expensive 1/8" vinyl for all masking. Once masked the sharpie wipes right off with denatured alcohol.

The green stuff in the picture is the sticky wrap. I had a half dozen mylar templates to replicate this scheme, only one is shown - the most complicated one. When all is said and done I think you'll agree that it is a process that works well.

BTW - If anyone wants to duplicate this scheme I'd be happy to lend my templates to them. They will most certainly work on any flash fuselage. Unfortunately, you'll either have to make your own templates for the stock tail scheme or cut your old Vstab off and make a new prettier one like mine so you can use my tail template
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Old 04-19-2013, 04:48 PM
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Default RE: ULTRA Ultra-Flash

beautiful job
Old 04-19-2013, 04:50 PM
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RC Larry-RCU
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Default RE: ULTRA Ultra-Flash

Lookiing GREAT Mitch!!!! Keep the pictures coming.
Old 04-19-2013, 05:25 PM
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Default RE: ULTRA Ultra-Flash

That's the best scheme I've seen on the UF yet.. Very nice! thanks for sharing
Old 04-20-2013, 02:54 AM
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mitchilito
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Default RE: ULTRA Ultra-Flash

Thanks guys. I couldn't be happier with how it turned out.
Old 04-20-2013, 06:41 AM
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mitchilito
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Default RE: ULTRA Ultra-Flash

I bought this jet used from a great modeler in sunny CA. As received it hadn't had the cockpit painted yet so I took this opportunity to personalize it. I sprayed the inside with flat grey primer and did a small amount of reorganizing. I love the look of the aft facing start and main solenoids joining at a Festo Y (just like I saw Dave Whilshire doing - thanks DW) so that's what I did. Again, I couldn't be happier with how it turned out.
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Old 04-21-2013, 01:16 PM
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mitchilito
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Default RE: ULTRA Ultra-Flash

It's finally time for the reveal. Overall I was very pleased with the final outcome. I have a friend who made the detail graphics for me but he is unable to do complex things. So for now the new Flash will be flying without the Thunderbirds emblem on the Vstab and the flag bar on the nose. I'm thinking of equipping myself for dry transfer decals but I'm not in any hurry.

I was a little nervous that my new tail would be heavier than stock negating the advantage the new Ultra wing affords - reduced nose weight due to increased sweep. I needn't have worried. In fact my new tail is as light or lighter than stock. Keep in mind my classic as flown used two 4000mah 2s lipos for the RX and one 4000 for the ECU- all of them as close to the nose as possible. In its current Ultra configuration I replaced the RX batts with two 2200s and had to move the ECU battery back beside the UAT (as seen in the cockpit pics). This is a radical departure from the way it was - and MUCH lighter! I also had to move the fuel pump farther back. It now lives under the front of the main tank.

Final all-up weight came in at 22.8 lbs dry. That's with a JetCat Titan SE (160 newtons). I adjusted battery position until my CG is right at 230mm back from wing/fuse junction in front. Even at 230 back it is not too far aft. I believe it could go back a couple more mm for totally neutral handling. At that point it would be nibbling at the ragged edge of tail heavy though. I was very pleased with the new Ultra Flash handling. It jumps off the ground much easier that before and full flap handling is completely straight forward - the opposite of the CF.

Bottom line: I'm very happy with my new toy airplane
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Old 04-21-2013, 10:31 PM
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Default RE: ULTRA Ultra-Flash

Currently you own the prettiest UF on the planet IMO. Love the way this scheme elongates the canopy, especially with the tinted glass. I will probably repaint mine this coming winter, I planned on doing this scheme, but struggle deciding if I should do a custom never seen scheme. Great job!
Old 04-21-2013, 10:32 PM
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Default RE: ULTRA Ultra-Flash

Nicely done! Tbirds looks great on the Flash/Ultra Flash.
Old 04-22-2013, 01:57 AM
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mitchilito
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Default RE: ULTRA Ultra-Flash

ORIGINAL: BlueBus320

Currently you own the prettiest UF on the planet IMO. Love the way this scheme elongates the canopy, especially with the tinted glass. I will probably repaint mine this coming winter, I planned on doing this scheme, but struggle deciding if I should do a custom never seen scheme. Great job!
Thanks for the kind words, guys. Blue, if you decide to do the Tbirds let me know and I'll lend you my templates.
Old 04-22-2013, 07:20 AM
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Default RE: ULTRA Ultra-Flash


ORIGINAL: mitchilito

ORIGINAL: BlueBus320

Currently you own the prettiest UF on the planet IMO. Love the way this scheme elongates the canopy, especially with the tinted glass. I will probably repaint mine this coming winter, I planned on doing this scheme, but struggle deciding if I should do a custom never seen scheme. Great job!
Thanks for the kind words, guys. Blue, if you decide to do the Tbirds let me know and I'll lend you my templates.
That is really, really cool! I will keep that in mind, Thank You!
Old 04-22-2013, 05:46 PM
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RC Larry-RCU
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Default RE: ULTRA Ultra-Flash

Plane looks GREAT Mitch! Looking forward to seeing it at Wilson's "First In Flight" soon!
Hey,,,,,,,,,,,,,,, How about a really cool Jackie Sacks Wing Bag to keep that beauty all safe and sound? ( yea,,,I know,,,Cheap Plug! ) lol
But ANYway,,,,, Jacqui finished up your Ultra Flash Wing Bag tonight. Should be getting shipped out by Wednesday.
And again,,,GREAT job on the re-build. If you're not careful guys are gonna start sending their wrecked jets to you for repairs!

Larry
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