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HomeScaleAircraftScale HeliScale Helicopter Main Discussion Docs  Airwolf Turbine - My Build
11-30-2015 06:56 AM  34 months agoPost 181
Double E

rrApprentice

Atlanta, GA

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Congratulations Steve. I can't wait to see you roll and flip the wolf at Dalton 2016. 😈😀

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11-30-2015 12:45 PM  34 months agoPost 182
doorman

rrProfessor

Sherwood, Arkansas

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Outstanding!!
That is all good news Steve!!
Solid in that kind of wind is a good thing....
Glad your back on track.... sometimes these models can give you "fits", but I know you were grinning from ear to ear during the last tests!!
Go get those knockoff parts done!!(any part that is mounted on the outside of the fuselage, that can easily be " knocked off"!!)
Stan

AMA 2918-Team Spin Blades,,Castle Creations, Unique Aircraft

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11-30-2015 08:34 PM  34 months agoPost 183
ssmith512

rrKey Veteran

Indianapolis, IN USA

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Thanks Eric and Stan!!

Wasnt perfect by any means, but a step in the right direction I think.

Flip and roll the Wolf? Hmmm. Wonder if I can get an insurance policy on Wolfie that includes peer pressure induced damage? LOL!!

Steve

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12-01-2015 01:00 AM  34 months agoPost 184
Double E

rrApprentice

Atlanta, GA

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Steve,

Don't worry, you won't be seeing me fly any inverted aerobatics with my Huey. At least not on purpose anyways.

I did however place an order with Joe at East Coast for one of the Vario Bo-105 kits for Trex 700 mechanics. That will be my designated aerobatic scale helicopter.

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12-01-2015 01:12 AM  34 months agoPost 185
ssmith512

rrKey Veteran

Indianapolis, IN USA

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I did however place an order with Joe at East Coast for one of the Vario Bo-105 kits for Trex 700 mechanics. That will be my designated aerobatic scale helicopter.
Sweet!! I took advantage of the Black Friday sales and ordered mechanics, motor, servos, and ESC for mine. Hopefully the heli Gods will be good to us both and allow us to have them in flying condition by Dalton next year. Can you say SHOWTIME!!

Steve

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12-06-2015 06:23 PM  34 months agoPost 186
ssmith512

rrKey Veteran

Indianapolis, IN USA

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Welp, mechanics are out of the fuse and we have officially started the hard part of the build!! Detailing and prep for paint - YEA!!!! :-)

Nothing done yet, but figured I would post what is in progress.

First up, the tail surfaces. The kit pieces are very nice, but unfortunately they are the profile of a Bell 430. Airwolf was of course a Bell 222 and I decided that I just wouldnt be pleased flying around a Bell 222/430 hybrid. So we start modifying. Here is the vertical fin stock piece on the left and the template of what it should end up looking like (hopefully)....

Started off by chopping the lower and upper portion off to give it the proper height. Then I split the trailing edge and constructed some extension pieces out of balsa. I used preshaped trailing edge balsa....

Various pics of adding the extensions...

Extensions glued in place and ready to be roughed into shape....

First coat of bondo before sanding.....

Round one of sanding complete......

Stock winglet shown on the left, Bell 22 profile on the right....

I rough cut the winglets out of 3/16" light ply....

I will add trailing edge pieces to the winglets and sand them to shape (havent gotten that far yet).

The chord length on the horizontal stab is too narrow as well, so I added some extension pieces to it, using the same process as the vertical fin. They are left long for the time being until I am ready to fit the winglets....

Now it is just a matter of filling, sanding, filling and sanding to get the the correct profiles and take care of any imperfections before primer.

On to the doghouse. First thing was to get the holes cut for the exhaust. This process kicked me in the butt as I had absolutely no idea how to go about locating the holes. It is one of those "chicken-before-the-egg" / "catch 22" situations. The exhaust exits at two angles and through multiple compound curves on the doghouse. They also exit the sides of the removable doghouse so I needed to split the doghouse in order to be able to get the doghouse on and off as needed.

Started by making some card stock templates...

Templates complete......

Transferring the template outline to the doghouse in preparation for cutting....

Idea was to get the template as close the outline of the exhaust.

Holes rough cut. Turned out pretty good......


Those are not the final holes. The final holes will actually be larger that I will hand sand to final fitting and give me about a 6mm clearance between the exhaust and the fuselage. Will be a nice tight fit, which is what I want.

That's it for now. Off to go do more filling and sanding!

Steve

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12-06-2015 10:19 PM  34 months agoPost 187
Keygrigger

rrVeteran

Mississauga, Ont. Canada

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I bet you were hoping your shorts didn't fill up when you started those holes. Nice reworking of the tail surfaces and exhaust holes. It is pretty much time to start mine. Take care.

Don

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12-06-2015 10:51 PM  34 months agoPost 188
Copter Doctor

rrProfessor

Enterprise/ft.rucker ,al- home of army aviation

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Looking good steve!!

drive a rotary, fly a rotorcraft

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12-07-2015 03:30 AM  34 months agoPost 189
doorman

rrProfessor

Sherwood, Arkansas

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Sweet!!!

AMA 2918-Team Spin Blades,,Castle Creations, Unique Aircraft

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12-07-2015 03:35 AM  34 months agoPost 190
Thumper217

rrApprentice

Slidell, LA - USA

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I like what you did with the card stock, taping several pieces together to get the right shape on the compound curves. Thanks for sharing that.

AM

Thumper

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12-07-2015 08:47 PM  34 months agoPost 191
ssmith512

rrKey Veteran

Indianapolis, IN USA

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I like what you did with the card stock, taping several pieces together to get the right shape on the compound curves. Thanks for sharing that.
It was the only way I knew of doing such a complex ovoid shape, given the tight tolerances I wanted to maintain.

Steve

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12-07-2015 08:52 PM  34 months agoPost 192
ssmith512

rrKey Veteran

Indianapolis, IN USA

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I bet you were hoping your shorts didn't fill up when you started those holes. Nice reworking of the tail surfaces and exhaust holes. It is pretty much time to start mine. Take care.
Indeed, but I am learning that I needn't fret so much. I have learned that an error in cutting a hole in the wrong place or the wrong size is "relatively" easy to fix with a little foam/fiberglass/hysol/sanding putty/etc. Obviously I am taking the extra steps to prevent as much as possible the need for said "repairs".

Steve

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12-13-2015 01:40 AM  33 months agoPost 193
ssmith512

rrKey Veteran

Indianapolis, IN USA

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Body work body work, nothing but body work. What a painfully slow process. Sand, bondo, wait, sand, bondo, wait....repeat, repeat, repeat. Ugh. But a very necessary step as the time spent now will result in a flawless paint job.

More work on the extended and reprofiled vertical fin. 3 coats of bondo and I think I am close enough for primer....


Cut out the top and bottom caps. The 1/4" ply piece you see on the bottom cap is reinforcement for the tail skid pipe. This will give me a good solid mount for when I fab and install it...

And the caps being glued in place. They are purposely oversized and will be sanded to shape after the hysol drys.........


3 coats of bondo on the extended horizontal stab and again I think I am close enough for primer.....


Got the inlets cut out in the doghouse.......


Tomorrow I am gonna change it up a bit and start on some body work! LOL!!!

Steve

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12-13-2015 04:36 AM  33 months agoPost 194
doorman

rrProfessor

Sherwood, Arkansas

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About Time
I was really needing a pic of hysol drying!!!
Really looking good too!!

Stan

AMA 2918-Team Spin Blades,,Castle Creations, Unique Aircraft

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12-13-2015 06:08 PM  33 months agoPost 195
ssmith512

rrKey Veteran

Indianapolis, IN USA

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Started working on filling in the turbo hatches. Vario gives you the option of having access hatches in these locations, but I have nothing to access, so they need to be filled in......



Also finished up the the top and bottom caps on the vertical fin......


And was able to start sanding down most of the fuse seams.......

Time for some football. Then more sanding and filling over the next 2 to 3 years!! LOL!

Steve

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12-20-2015 10:22 PM  33 months agoPost 196
ssmith512

rrKey Veteran

Indianapolis, IN USA

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MAJOR FAIL ALERT!!!!!!

Well you have to fall from the tree every now and then to learn a lesson and I had a fall. Fortunately I drink lots of milk so my bones are nice and strong and am able to bounce right up and continue on my Airwolf journey.

Lets look at the doghouse in her stock form.....

Because of the location of the exhaust outlets (down on the side of the doghouse), I cant really drop the doghouse straight down. I need to "flare out" the sides during assembly to get the doghouse around the exhaust. I also need to access this area in the fuse to install the intermediate tail drive shaft during assembly/disassembly of the removable tail boom at the field. So I decided to cut the top off the doghouse and "create" a removable hatch section. I started off by installing some guide rails and used the handy dandy micro-mark jigsaw and started cutting....

Instant hatch. Right?.......

Well kinda. But all was not well. I got way ahead of myself and ended up with a "hatch" that didnt fit worth a darn. What I failed to do prior to cutting was reinforce the doghouse - i.e. install some wooden formers on the inside or some carbon reinforcing, something to keep the doghouse and hatch shape during and after cutting. DOH!!!! Because I did not do that, once the hatch was cut, it kinda "unsprung" itself and I am now not able to get it to fit properly. The gaps are uneven and horribly large.....

Here is a close up of one of the gaps showing its size compared to an xacto #11 blade. Bad huh???

I tried various methods of spacer plates, alignment dowels, lots of magnets in various configurations and never came up with anything that I would be happy with, wasnt heavy as heck or I felt was a good long term solution.....

SOOOOOOOO. What I am thinking of doing is fitting the hatch as close as I can get it and then filling the gaps completely with hysol - gluing the hatch I cut out permanently back into place. A little fiberglass cloth on the inside to reinforce the joint. A little bondo and elbow grease on the outside and the major hatch fail should disappear.

But I still need a hatch, so I am thinking of reducing the size of the hatch considerably and putting it more on top where the doghouse is much flatter. Shown here outlined in the green tape.....

I will run some carbon cloth on the interior side of the doghouse at the new hatch location to reinforce everything prior to cutting. This new hatch will easily be retained by magnets at the rear and a retaining lip at the front. Maybe one recessed screw at the rear for added security.

What say you about the new plan? Am I back on the right track?

Steve

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12-20-2015 10:54 PM  33 months agoPost 197
Double E

rrApprentice

Atlanta, GA

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Steve,

We live and we learn. Sometimes it's a little painful, time consuming, and costly but we usually learn from it.

Based on your photos, would it be easier just to cut a small section directly below each exhaust hole so that you can drop the hatch down over the exhaust pipes. You could use screws, magnets or spring latches to re-attach the small sections once the doghouse is in place. Just thinking.

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12-20-2015 11:22 PM  33 months agoPost 198
ICUR1-2

rrElite Veteran

Ottawa, Ontario

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What say you about the new plan? Am I back on the right track?
kinda, make it a flush mount panel so the seems are near invisible
and to hide the gap.

just a thought

spending time, paying attention

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12-21-2015 12:44 AM  33 months agoPost 199
ssmith512

rrKey Veteran

Indianapolis, IN USA

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Based on your photos, would it be easier just to cut a small section directly below each exhaust hole so that you can drop the hatch down over the exhaust pipes. You could use screws, magnets or spring latches to re-attach the small sections once the doghouse is in place. Just thinking.
I had considered that idea long ago, and you are correct it would be a pretty simple solution, but I am a stubborn fool. Reason I did not pursue it was I felt that solution would require more screws for attachment and I am desperately trying to minimize the amount of visible screws in/on the doghouse. I have already modified some things from the Vario way of attaching the doghouse to eliminate some exposed screws. I know am creating my own grief because of it, but what the heck, call me crazy; I like the challenge!!

Steve

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12-21-2015 12:50 AM  33 months agoPost 200
ssmith512

rrKey Veteran

Indianapolis, IN USA

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kinda, make it a flush mount panel so the seems are near invisible
and to hide the gap.
If you mean that the removable panel and the surrounding surface on are on the same plane, then that is the intention. Making the gap as narrow as possible is the trick , but I have some ideas.

Thanks!

Steve

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HomeScaleAircraftScale HeliScale Helicopter Main Discussion Docs  Airwolf Turbine - My Build
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