Month: March 2015
Awhile back I started working on the rear turtle deck and it’s now time to complete it.
Former six made from RS-13 was cut using the provided template. Then was beveled to match the angle of the RS-5 stringers.
All of the formers were glued in place starting with F-6.
Once the formers were dry the stringers are glued to the formers. The stringers are glued to F-4&5 using the plywood stringer brackets. To ensure each stringer was straight I use cut a notch on the end of each stringer then pulled some string tight across the notches. Each bracket was adjusted until the stringer was straight with the string.
Some RS-7 blocks are glued in place to support the scalloped plywood cover on each end of the turtle deck.
Next I cut the scalloped plywood that covers each end and checked the fit. The rear piece I substituted with some plywood scrap of the same specification. Having the grain parallel to the tight bend was much easier.
Finally the scalloped plywood is glued in place. I tried to use only clamps but ended up needing some staples to hold it down.
The final result looks good.
Before extending the sides I drilled the hole for the starter pull string. It took a little effort to get the angle correct so the rope does not chafe on the wood.
To extend the sides of the fuselage I stapled a straight piece of plywood along the slanted fuselage side.
After carefully adjusting the depth on the router I used it to remove the plywood from the underlying RS-10
Now the plywood extensions can be glued onto the ledge created by the router.
To support the extensions two diagonal braces were added.
Because there was little glue area I added a gusset block.
Lastly some plywood was added on the inside so there are no ledges for debris to collect.
Now I can start fitting the fiberglass parts.
All that remains is to fit the fiberglass parts and fasten then in place.
One of the more frustrating aspects of this build has been the engine area. This airplane was originally designed for a Rotax engine and I am using a Hirth F-33. TEAM did provide some fuselage plans specifically for use with the Hirth but they need refined because things just don’t fit together properly.
The upper fiberglass does not fit unless the engine is moved forward. To accomplish this I modified the engine mounting plate. The original is sitting on top of the modified one.
The four holes for the engine were simply moved forward by four inches.
With the engine forward the upper cowl is fitting better. If the top width of the fuselage at station two was a couple inches less it would fit perfect but it’s too late to make such changes.
Now for the next problem, the front of the fuselage is angled leaving nothing to attach the lower cowl onto.
The angle is needed so the hot air from the engine has some place to go but the fuselage sides need to be square like the plans for the rotax engine. Had I thought of this problem earlier I would not have trimmed the plywood sides so it would look more like this.
Looks like I will be extending the sides to make this work but the first step is to complete the front of the fuselage behind the engine.
I started by adding a couple of blocks in the front corner so I have something to glue the plywood onto.
A piece of 1/8″ plywood was cut to fit vertically across the opening with the sides glued to the newly added blocks.
Another piece of wood was shaped to reinforce the bottom of the plywood and provide a glue surface for the angled piece.
Finally the angled piece is added sealing the fuselage nose.
The next step will be to extend the fuselage sides to meet up with the lower cowl.
Just a few more steps to complete the right wing. I first attached the RS-534 plywood cap on each end of the wing being careful to ensure the plywood lines up on the wing and aileron.
Once the glue was dry and staples removed the plywood was tapered to make a smooth transition.
A slot was cut on the wing bottom of the root side so the control horn can be mounted. The needs to be long enough for the horn to be slid in from the bottom.
I am considering building some hatches to make access to the strut mounting bolts easier.