As far as anyone in Germany or Switzerland having built even one wing that is designed to operate in the speed range that mine will and although they do have some microlight aircraft their aircraft do not meet the specs for the USA FAR 103 ultralight specifications for weight or speed range. can weigh a maximum of 254 pounds, and should not be capable of more than 55 knots in full power level flight, while having a stall speed that does not exceed 24 knots. Cutting and Storing Fabric I cut all the straight lines with an exacto, some of the curves too. Stack Exchange Network. The hinges need to be cut on a bias, this is to align the fibers in the best possible way to create a hinge. 713K views 11 years ago Part 0 (a basic intro to the Armin Wing concept). A subsequent "improved" version followed, named the Whing Ding II. If it sits at some mid-span point and its only function is to keep the wing skin in the right shape, loads on the rib are indeed low. old hippie methods? I raise an eyebrow at most of these entries. A sturdy steel and aluminum construction, removable doors/windows and folding wings and tail complete the priced-just-right package. surely very eko friendlyand millions of km of new copper cables for charging stationsall that is powered by fossile fuels for the engines, trucks and machinery to dig the ores, coal for processing amd so basically all a lie, not eko friendly at allat the contrary, as it doubles the need for ores and metals and fossile fuels for producing all that stuff, so combustion engines are lighter, need thereby less fuel at the emd amyways, don.t need extra mewly built faciluties and infrastructure and so onelectric propulsion is a lie! That pentane may be what your friend was referring to its either been replaced in most applications or is in the process of going there. Empty weight: 280-325 lbs. To fly under FAA Ultralight Rules (FAR Part 103), the single place aircraft must be used for recreational flights and have an empty weight of less than 254 pounds. Some people elect not to use PVA and only use wax. Its my understanding that the weight limits apply to the deflated balloon or blimp. Dont touch it. Asking for a friend . ? The foam itself does the job of the diagonal members in holding the caps in place and absorbing shear forces in the rib. You can use Value XPS to fold airfoil shapes by adding a layer of tape to support the leading edge curve during bending. I wish [Peter] the best of luck with this endeavor. During the pyrolysis, the nitrogen and . The wood rib has the primary compression and tension members in the capstrip, with the diagonals absorbing shear loads, converted to compression and tension loads along the legs of the truss. Stack Exchange network consists of 181 Q&A . A strong and simple control horn can be made by threading a nylon aileron connector onto a 6-32 machine screw, then screwing it into the dowel. The maximum you can get is one atmosphere, which is roughly 1 bar, right? videos on youtube, interested in knowing approximate weight and range you got with that setup. on Step 3, How can we fabricate a wing that has movable control surfaces using composites like kevlar and the wingspan is 144inches and the control surface to be moved by servo motot. The foam is used to take small shearloads and support the primary structural element in absorbing tension and compression loads. Whether you need 1 set or a 100 set production run, Matney Models should be your source for high quality foam wing cores. You need to be a member in order to leave a comment. shows what is possible amd that authorities tell lies to keep people off from doing stuffand that many stuff was left out for speed and poweraviation was always about profut and warfare.slow airplanes, lightweight and cheap.no money to make! his batteries free! One neat way to do this is to make a small custom tool, for use with your foam cutter's power supply, or by inserting the tool into a soldering gun. This project also requires quite few tools and materials that can be difficult to gather. Foam does not provide a good material for hinging, so when you cut control surfaces for a foam core, you must face the trailing edge of the foam core, and the leading edge of the control surface with balsa. Trim Excess Away from Trailing Edge The excess must be trimmed away with a exacto and a straight edge.Cut Hinge Line To cut the hinge line, carefully line up a straight edge on the top of the wing and slice down to the kevlar strip on the bottom surface on the wing. Next, the practicality and engineering. Make sure all the layers are in the right order, then turn on the vacuum and set the pressure. Think about that the next time someone brings up the Part 107 drone certification. I believe that it would be lighter to use the leading edge "D" box spar and the rear spar that the flaps will hinge on as the load elements and attach the wing to the top of the fusalage and with struts at some length of the span for twist prevention and longtitudinal stability. If there's an appropriate opening in the part, you can simply dig out the foam, being careful not to damage your fiberglass shell. The "negatives" can be used to store the completed wing perfectly. bcs carbon is lighter than glassand has high strength, but you forget that epixy is stull heavy! . on Step 8, How can we make the wing with movable control surfaces using this process, Question What are the penaltys if you was to get caught flying a light sport aircraft with a passenger with out any licensing at all , i live in alaska, After seeing the U-tube video, I now have to have one. There are several commercial devices made for cutting foam wing cores and other parts. The blowing agent in a sheet production system may be something much simpler much closer to one of the R-xxx refrigerants/aerosol propellants. Visit my 3D Modeling-related site at mikejamesmedia.com, Home | News | 3D Model Catalog | Costs | About | Products. Finally, you would probably tack glue the surface back onto the wing, and sand to the proper shape. Bud Bennett has updated the log for Seismometer. Why were most of the first-generation-Learjet wing mods never approved for the Learjet 23? I am in the process of design of an ultralight plane for which I only have some of the skills needed. Thank you for the concern. If the foam rib is inside a stressed skin wing, the stressed skin is effectively the cap strip and the foam can be bonded directly to it. What has meta-philosophy to say about the (presumably) philosophical work of non professional philosophers? Very slick, and much easier to maintain precise fit and alignment. Im building my first light sport aircraft and its one step above an ultralight and I wanted to have high back country bush stol capabilities and I would like to know if I should incorporate flaps with my ailerons or should I just run with flapperons what would be the advantages not knowing and at the risk of sounding stupid. itls harmful to the environment, just when you consider charging losses of 20% every time sou use any kind of batterie, production and twice the weight all he proves is that it can be donewhen you use 2 cheap RC 160 ccm engines they hold on for 50 hrs u til they need a rebuild amd then you have 16-20 hp easilyand not 5-8his one had merely 5 kw! Because its going to be incorporated into a house there are some pretty strict standards about reactivity, VOC and outgassing no bueno if it makes people sick both in the factory or at home, or causes the shower stall to come apart. In one afternoon, I cut foam wing cores, assembled the sheeting, and had this shape, which is a lot more precise, and less expensive. Reynolds number is more important. If your aircrafts empty weight is over 254 pounds, you will be flying under GA Rules (Part 61 & 91). These are shown in blue, above. The answer depends on the wing loading of the aircraft. I am in the process of design of an ultralight plane for which I only have some of the skills needed. This gives you repeatability, which makes sense for a complex project. What gives? Preparing Everything as much as Possible Before you mix your epoxy, make sure and prep everything possible to ensure you have enough working time. Like most other composites, the use of foam in models has a specific purpose. and I ordered my bagging materials from CST: Ill add that, Thanks Charlie. Free shipping. There are motors out there. It is based off the Mark III Classic design with some aerodynamic enhancements to generate an extra 10-15 mph cruise speed. The maximum approved gross weight for a two-place ultralight is 1,320 pounds. well, crowdfunding is easier than carreer.others waste their life with work, many simply collect money for free and call it a society or club.an old parachute costs some mere hundred dollars.he flys at 10 m highton 5-8 hpthe parachute is useless! It is known for its versatility, light weight, sporty handling and rapid climb rate. That is produced by phantom aeronautics of Three Rivers Michigan and is available in kit form. Here's an image you've seen many times, showing the profile of a foam wing and aileron. Then design the Ailerons that will take control of the aircraft with the fuel moving outward to inward in knowing where the center of gravity of your aircraft is fully loaded. How do you apply 10 bar pressure using vacuum? Peters plane will never get enough air time for fatigue to be an issue. My current idea is to use a Polystyrene foam core ( 6" x 2" cross section) and laminate it with 1 layer of 12k carbon fiber, and vacuum infuse epoxy resin. The options for the Airbike include various engines, folding wings brakes, trim, wheel pants, wing tips bucket seat, extra fuel, plus various quick build and assembly packages. $17,800 ATF Light Soaring Trike with 200cc Minari engine - Solairus 16.8M Wing. Both Upper and lower wing are removed as well as rear horizontal stabilizer. Then cut some lengths of yellow nyrod to fit, and epoxy these through the tube and into the elevator halves. 3-6 coats should do it. $18.44. Having said that, it has it's place in modeling, especially in the case of making plugs for molds. ) so what plqns do you need? so everoyne dould build and fly freely! A Pocket Sundial From a Broken Pocket Watch! The purple "dot' in the image is another item you may want to add, which is a hardwood dowel, epoxied into the leading edge of the control surface, which will serve as a mounting for a control horn. Pegasus H-3 The H-3 Pegasus is a low-wing, open cockpit monoplane by noted lightweight sportplane designer Bert Howland. A few years ago, [Peter] built a gigantic remote-controlled cargo planeout of what is basically foam board and a few aluminum tubes. Rock Paper Scissors Using Tinkercad Circuits and Arduino, Punchy the MECH & the Autonomous Fight Club. Not at all. Stack Exchange network consists of 181 Q&A communities including Stack Overflow, the largest, most trusted online community for developers to learn, share their knowledge, and build their careers. what elsei want 2 ums 16 hp radials for free too, each is 2,8-3,2kand i want the same rules for ULs where i live or a free visa to fly in the US tooyes.we all can wantbut realuty sucks! . You have contributed to experimental and ultralight aviation and advanced our pool of knowledge. I expect he will have to do some stress tests before first flight ;-), But I prefer Arnold AR-5 structure and design, whats a beautiful plane, take a look : https://airscapemag.com/2016/12/05/arnold-ar5/, Great project! Sometimes, depending on the layup schedule, scoring the bottom surface of the wing might be required.Sand Hinge Line I used a foam sanding block to create the space for negative aileron deflection. The foam is weatherproof, easy to form, and less rigid than Depron, but more flexible. Dealing with hard questions during a software developer interview. It's what I do with all my original designs.The process is long and tedious, but once you're done, you're really done! pls don.t dump us as trollswe are warning and asking why certain stuff was done so crudely, why everyone hypes idiotic electric propulsion and keeps the environmental destruction needed for all the materials and uranium ore ozt of the equation, why we still seesooo wel done styrofoam construction when hundreds of ULs fall out of the sky, why we have so many rules without any sense but on the other hand nobody changes the hazzardous methods called provem and reliable! The design of this aircraft is an electric, twin-engine biplane. With the Hi-Temp release wax I used, I waxed on, let dry for about 30-60 seconds, then buffed off. I'm starting this process with the wing spar. In a composite structure, the foam serves the purpose of providing a shape, while the material that surrounds it serves the purpose of providing the strength. It breaks. Foam wing Sheeting demonstrates how I sheet foam wings with balsa. The finished weight on this set of wings is 129.9 grams. and insert them into the slot you've made. Keeping that in mind, we have put together a list of the top 3 single place (seat) and two place ultralight aircraft currently available. It looks like the fiberglass and aluminium are the worst in terms of fatigue problems. How To Make Plugs For MoldsDifferently. How would I go about calculating the strength of a wooden spar that is 5 inches high, has a web thickness of 1/8" and a top and bottom cap of 1.5" x .75"? The FireFly also offers the mainstay features all Kolb aircraft are known for: quick-folding wings, enclosable cockpit, welded chrome-moly steel fuselage cage and, of course, outstanding performance. One more at 9 inches high, 1/8" web, and the same top and bottom caps. Hotwire to shape the foam into aerodynamic shapes is easy and repeatable. But you succeeded! Id like a solar powered ultralight anyone try converting one? Standard features include an open cockpit, removable wings, steerable tail wheel, 4 point safety harness, fuel tank, factory welded fuselage and tail. like those batteriesand heavy motors.one 8 hp RC engine with 160 ccm weights 8 lbsinkl. cant believe I left it out. Cell size 1.4 mm to 2.4 mm. The spindles are pre-welded and drilled for easy installation. and he shows what is possible against the maistream.the rest is kinda dangerous. It might also be useful to build a CNC flat table hot wire foam cutter to reduce the foam to be cut by CNC Bit Cutter. You are an encourager to others! Even given that there was an abundance of information and materials to work with since flight first began in America, you are still a pioneer. Tests are invaluable. There are a lot of types, but extruded polystyrene (XPS) is common in the US. Plywood sold for aircraft construction guarantees some minimum strength, allowing to compute a beam much like is done for metals. The improved version incorporated a higher seat to prevent the pilot's feet from dragging on the ground. Suspension Styrofoam 2 lbs/ft 0.2 lbs/ft density. Some are serious contenders sponsored by universities and clubs and some are little more than costumes put on by individuals, but all eventually end up in the lake to great applause by the audience. I have seen several YouTube videos of ultralights and even HPAs (Human Powered Aircraft) that use foam as the ribs of their wings. Be careful not to add too much spray paint, because it will add weight to the finished wing. crazy! The Wingspan is 38.5 inches. 6/3/2022 $800.00. The Phantom x1 was introduced in 1982 as a single-engine tractor configuration single-seat, high wing and tricycle gear ultralight aircraft. take care, and blue skys! The airfoil above operates well in the range between 24 and 64 MPH according to the NASA Foilsim program and Aeval software. Japan hosts a Japan International Birdman Rally over Lake Biwa every year where anyone can build a man-carrying ultralight and fly it, albeit once, off a dock for distance and entertainment value. What is a good price ? Four axis CNC milling Prepare Templates Paper templates are made in all the shapes of the fabric that need to be cut out, card stock or index makes for the best tracing paper.Trace Templates on the Fabric Tracing on the fiberglass and kevlar is pretty straight foreword. Make sure you measure out your epoxy precisely and mix it thoroughly to ensure the strongest finished structure. Cutting Templates I cut my airfoil templates using my CNC machine. Pictured above is 2004 EAA Sun-N-Fun For the last hundred years, the default wood for aircraft has been either spruce or douglasfir. Is email scraping still a thing for spammers. Lengthwise reinforcements using glass rovings on the top and bottom side of the rib improve its bending strength. Can "a drone" damage the wing of "an aeroplane" to the extent it actually threatens its ability to fly? First, finish gluing the joiner directly to the stabilizer halves with a little epoxy. I use a 1/4 inch carbon fiber tube for most of mine, but you could use a rigid wire, or other material, depending on the size of the elevator assembly. The wing will be fabric covered so the covering is not structural. These test parts are approximately 4 inches square. I have 1 two place (for sale) and also 6 others. Yes, this ultralight is constructed out of insulation foam, but you can think of that as just a skin. And with all of the modern materials and so much work being done by so many experimental builders over the years there is a wealth of information out there. I also cut out the doors, and did some testing to decide how we would hinge them, and how we would operate them. Gross weight of the Pegasus is between 500 and . So far, everything is not as sketchy as it could be. This foam and wood build will be wrapped with carbon fiber and fiberglass sheet, epoxied, and hopefully painted with flames on the side. If it passes static it will be strong enough.. (relatively) slow cruise speed and a massive 7gph fuel consumption. I will use Junker style ailerons and ungapped hinged simple flaps. Finally, I incorporated it into the "Eliminator 2" vertical fin, and on the other wing and tail parts. Is Rutan's method of foam core construction obsolete? Here is an example of such a system, this one uses a drop bar:http://www.acpsales.com/Feather-Cut.htmlSanding Wing Cores Smooth After the wing cores are cut, little hairs will be left over. NOTE: I am not at liberty to redistribute any of the documentation used to build any of the 3D models on this site. I see no point in solar panels on board, I suppose you might be able to squeeze out 5 more mins in an hour flight? I have also had the privilege of talking with a number of modelers and taking bits and pieces from each of them to come up with the following way that I . Instead, I make a series of simple and inexpensive tests first, refine the idea, then finally use it on a model. The Firestar is one of Kolb Aircraft's classic proven designs and has been in production since 1985. A six foot chord and a 30 foot span provides for lift at 24 mph (14 with flaps down) and low drag co-efficient at the maximum level flight speed of 64 MPH. Foam on it's own is not structural. What type of insulation foam is used in these aircraft? He is very overt about his Thai background and the restaurant his family owns. The airplane has a 22-foot wingspan, is 17 feet long, and is powered by batteries. The narrow fuselage means that the rudder pedals are on the outside of the aircraft, giving the pilot the appearance of riding a motorcycle hence the inspiration for the Air-Bike name. (Use the appropriate type of wire for your power requirements, and use caution.). The relevant calculations have already been done, and [Peter] is already flying an RC scale model of this craft. No, X86 Single-Board Computer! bending wings made from willow and ash! Sponsored. Pour foam and urethane foam for non-structural parts (fairings and such) to H45 Divinycell for the fuselage sides. Connect and share knowledge within a single location that is structured and easy to search. The real structure here comes from a wooden frame that. About: I got started making remote controlled airplanes from scratch as a kid. It is also easily fiberglassed, using either polyester resin or epoxy. Waxing the Templates The mylar templates must be prepared before they can be used to make parts to ensure that they do not stick to the wing. How can filling the empennage (aluminium tube) with Styrofoam stiffen it to avoid buckling as seen in Whingding ultralight? and so onand so on When the epoxy is cured and the wing is sanded to shape, you now have "built-in" control surfaces! . Im guessing the finished weight of this model will be around 375-400g depending on the battery I choose. Contact Brendan@usysinc.com, Can you describe how you painting the wing? This greatly helps to reduce the finished weight of the part.Placing Cores After the epoxy is evenly spread, the foam cores are placed on the bottom of the wing, then I flip the top mylar over on-top of the foam core and carefully place in the vacuum bag. For a rectangular wing it's at. The order of the layers placed in the bagBAG Breather Cloth Peel Ply Mylar Fiberglass Carbon Parts Foam Core Carbon Parts/Kevlar Hinge Fiberglass Mylar Peel Ply Breather ClothBAG This is where the table would be. I will close by pointing out that two bicycle mechanics figured out how to fly well by understanding aerodynamics were king while simultaneously beating out a huge government funded push to create a controllable airplane headed up by a man with the familiar name Langley who insisted horsepower was what was needed. Yeah, we all HATE that crap from Discovery and NatGeo. rev2023.3.1.43269. The second category of ultralight aircraft is two place or two seaters. his birdsshort lived bcs they will fall apart within 2 yrs or simply become a hazzard when binding surfaces and joints weaken in no timebut who cares [Peter Sripol] is something of a legend in the DIY RC aircraft crowd. Btw: The Velocity aircraft was conceived on that simulator, As I understand it, X planes builder and flight characteristics are based on the plank method and are not as accurate as XFLR5 for design analysis. 1 1/2 inch single pull buckle. 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Thread starter pilotnick12; Start date Sep 2, 2013; Tags design foam homebuilt ultralight ultralight design 1; 2; Next. The ultralights can be unpowered gliders or man-powered, never motored. ask a civil ingenieer abozt construction, they will laugh at the idiocies done at airpkanes amd carsdon.t ask architects, thise are just designersartists! (Hence the 2000->200 test). It's made out of insulation foam. Then design the Ailerons that will take control of the aircraft with the fuel moving outward to inward in knowing where the center of gravity of your aircraft is fully loaded. He is in the midst of building his 2nd attempt at a scratch built ultralight now. It was the first fully enclosed ultralight on the market and has become a time-honored classic. When I install these on the actual model, all the guesswork will be done, and we know they'll work right. How do wing ribs withstand lateral lift force? even PU foam cores delaminate simply bcs the guys or girls designing so desperately witj fiberglass( heavy) and carbon laminates( heavy as such, but not bcs of the carbonbut bcs epoxy soaks i to tje foam and epoxy is heavier than waterand needs a minimum thickness, so it,s useless under compression.the rest is taken by foamcores , low rated G loads or you need very thick wingrootsthat easy! ) Do you paint onto the wing directly? Pitts S1C Biplane no Engine Airplanes. Make sure that it will takr the landing wheel loading and cycles you need if you have wheels. Hope Peter is planning on releasing the plans when hes done like the rest of the FT designs! Its wood, composite and fabric. By clicking Accept all cookies, you agree Stack Exchange can store cookies on your device and disclose information in accordance with our Cookie Policy.