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New CARF P-51D Project

Old 05-12-2017, 10:27 AM
  #51  
Chris Nicastro
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Haha nice, hey did you say you're using Rhino for CAD?
Old 05-12-2017, 10:28 AM
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We have crap weather all weekend I should just drive over and pick them up!
Old 05-12-2017, 10:41 AM
  #53  
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Rhino was too much for what I am doing. Fusion 360 has been awesome. It has a CAM package as well, so when I get the CNC router this fall, I'll already have a rough idea of the software.
Old 05-12-2017, 07:03 PM
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Is that an onboard starter on the motor?????
Old 05-12-2017, 11:04 PM
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Yes it is!
I have an 85A ESC and 3cell LiPo for it. The battery will hook up externally to keep it a little lighter.
Old 05-13-2017, 10:50 PM
  #56  
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The two carbon longerons are in now. I used wax paper to help smooth and spread the resin but there are some areas to remove excess resin, no big deal. Already the fuse is much more stable. The radio tray will further help reduce twisting once it's installed .
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Old 05-29-2017, 11:08 PM
  #57  
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Got some work done today. The servo tray is coming along and I made and installed a bulkhead for it.
Also figured out some ideas on the cockpit. I got the detailed panels and spliced them together to make one from two.
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Old 05-30-2017, 04:25 PM
  #58  
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Here's the tail cover with the gear doors. Pretty easy to do it this way. Taped the doors in place but didn't cut the center seam until after the epoxy cured. Then I cut the doors apart and relieved the outside edges to allow them to move.
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Old 05-30-2017, 04:26 PM
  #59  
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One more..
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Old 06-10-2017, 04:32 PM
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Update on the tail section, the radio tray is coming together. The rudder servo is also steering the tail wheel. The upper surface is going to have the two regulators and battery packs at this point. The bottom will have the Rx and the second air valve.
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Old 06-10-2017, 04:34 PM
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You can also see the elevator servo is pretty hidden in the root of the stab. I epoxied two 1/4 inch ply servo mounts in at about 30mm from the edge.
Old 07-02-2017, 02:26 PM
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Details of the stab set up. Pretty clean and simple, there are ply blocks epoxied into the stab for servo mounts. Initially I was going to use the heavy duty plastic servo horn included with the servos but the clevis pin isn't long enough to lock in place. The larger metric clevis supplied by CARF have same pin length as the Sullivan clevis so the better choice is the blue aluminum servo horn included. The pin hole is tight but working it through with a drop of oil made it go through.

In the fuse at the base of the stab I put a gromit in the hole to protect the servo wires, both sides.
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Old 07-02-2017, 02:35 PM
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Laid up carbon fiber to strengthen the nose section. I used three different carbon fabrics. One is a ribbon, one is the 12x6K special weave and the last is 6Kx6K stitched two layer fabric. The 6x6 conforms to compound curves really well, cool stuff.
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Old 07-02-2017, 02:40 PM
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The KOLM supplied firewall is all but unusable so I have to design a new one. I'm using it for a template. Unless this gets a total update don't bother getting the kit.
Im planning a full baffle and airbox build. After the firewall there will be two floors and a duct. One floor will be for the tank and servos. The second floor will be for the cockpit. The duct will be from the wing bolt back to the radiator exhaust.
Old 07-02-2017, 02:42 PM
  #65  
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Pics of the firewall
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Old 07-07-2017, 06:35 AM
  #66  
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Hi Chris,

Really nice work mate. Keep the pics coming. I have one to build so I am watching with interest.
Old 07-07-2017, 06:42 AM
  #67  
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Originally Posted by DrScoles
Its got a ZDZ 100 in it. Pain in the ass, I thought it would be easier than the Kolm... having second thoughts. LOL I designed and printed machine guns for the Mustang. Been using the 3D printer for a lot of things. Used it to make the servo mounts for the flaps and ailerons as well.
Haha...Mike I bought a ZDZ 80 twin for mine with a keel exhaust before I bought the kolm. I still have it in the box upstairs. Why didn't you want a kolm in your second one?
Old 07-07-2017, 06:44 AM
  #68  
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Interesting to see that Kolm redesigned the whole ducting system to direct cool air over the carb side of the engine. I bought that kit recently as it seemed to make much more sense to me to do it that way. Carbs will be much happier with cool air I think.
Old 07-07-2017, 02:35 PM
  #69  
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Originally Posted by Chris Nicastro
Laid up carbon fiber to strengthen the nose section. I used three different carbon fabrics. One is a ribbon, one is the 12x6K special weave and the last is 6Kx6K stitched two layer fabric. The 6x6 conforms to compound curves really well, cool stuff.
Hi Chris-
Where did you pick up the 6x6 CF cloth from ?
Thanks-Mike
Old 07-07-2017, 08:33 PM
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Thanks Craig, lots of work if your going with a big engine for sure!
Im making an air box around the carbs with a cold air inlet I think. Haven't posted pics yet but I'm making a duct thru the plane to draw hot air out too.

Mike, the 6x6 fabric was a sample given to me by a friend. He's into aerospace composite materials and retired from the airlines. This fabric is pretty high end. It's two layers of 6K stitched at about 90 degrees relative to each other. It conforms to compound curve surfaces really well. I'm not sure you can buy it in small quantities or even find it in a catalog. He gets samples or remnants from big companies and sometimes doesn't even know what it's for.
I used West Systems epoxy with the fast catalyst on this fabric, turned out very tough.
Old 07-08-2017, 06:59 AM
  #71  
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Hey Craig, the second mustang is my friends. Just helping him get it done. I flew the my Mustang two more times last week. Two of the motor mount bolts backed out! I put lock nuts on top of the blind nuts on the top two, and one of the bottoms. This thing vibrates violently at idle... LOL Take any plane you've built and make it twice as strong. Most of the mounting plates I've put in with hysol have broken free. Arguable if you should use ZAP to glue some stuff in for vibration damping. This is one of those planes that for every few flights you have, you'll earn an hour of maintenance, gotta stay on top of it.

The mustang flies very well and I still get a huge smile on my face on flybys... the sound is so distinct. Having an electric starter is awesome as well...

Chris, stinks the mounting kit is not up to par. I had the exact same problem, but I attributed it to them sending me the wrong length motor.... It will be interesting to see how this plane does with the three cylinder.

Headed back out with it today :-)
Old 07-08-2017, 08:19 AM
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Hey Mike, thanks for the parts!
Yeah rub it in, flying today, I'll be building this weekend...
Old 07-08-2017, 08:27 AM
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One thing I'm doing on all the engine bolts is cross drilling the heads and using safety wire. I've been doing this off and on with various engines over time and it does work. With two DLE 55 with side exhaust and Pitts style muffler I had two experiences in two different planes. In a Mustang without safety wiring the bolts it would come loose after 3-5 flights regardless. On an Ultimate with the same set up, different engine, I decided to drill the bolts and wire them plus a drop of thread lock. So far with a few hard aerobatic flights the muffler is still snug tight.
I plan to wire up as many screws as I can on this project! Even the fuel lines!
Old 07-09-2017, 01:44 PM
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Firewall is in now. I went ahead and committed the soft mounts with threadloc and safety wire because it was easier to do now.

I found out more info about the 6k x 6k fabric. It's called VectorPly, C-BX 1200-5.
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Old 07-09-2017, 06:33 PM
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First time the engine is in the airframe, pretty awesome sight!

The foam block is the rear duct part. This is just a third of the duct system.
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Last edited by Chris Nicastro; 07-10-2017 at 12:27 AM.

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