Aerotech 42% - Twin Build

[Fixed Wing]

Jonas,

Your Dalton is really looking good. Looks like its going to come out super light. I'm excited for you to finish it and get it trimmed out for IMAC. Keep us posted of your progress. I have some ideas about my color scheme but haven't really locked it down yet. I'll share the scheme once its final.

Dan,

Not a dumb question. Notice in one of the pictures a 90 degree bend on the end of the piano wire. This bend butts up against the control surface. To keep it there I will either monokote over it or anchor it with a small screw and washer. I have done it both ways in the past and never had an issue with either method. I do seal the hinge lines anyway with a strip of monokote. If I want to ever remove the control surface then I just remove the sealing strip and replace it after I put the control surface back in place.

Dean

[Dangerous Dan]

Dean will you have one of these ready for little rock, would love to see it in person.

[Fixed Wing]

	Quote: Originally Posted by Dangerous Dan
	Dean will you have one of these ready for little rock, would love to see it in person.

I won't make it to Little Rock this year. I plan on flying at the Humble contest on 4/28. I sent you a PM.

Dean

[Fixed Wing]

Sorry I haven’t posted in a while but progress is still being made. All wings and stabs have had their leading and trailing edges cut, glued on, trimmed and shaped. No pictures were taken of these processes. Next it was time to cut out the ailerons and the elevators. The wings and horizontal stabs were each marked for all cut lines using a large template I drew on butcher paper. This template was then used to transfer the markings to the sheeted wings and stabs. This first series of pictures shows a wing being cut for the ailerons. The table being used has a perfect 90 degree edge so I used it as a bottom guide for the saw blade. A long piece of right angle aluminum was used as a guide for the top of the wing (actually its the bottom because the wing is upside down). The saw blade is a hack saw metal blade which makes a very fine cut. I realize that other people use band saws, etc. for cutting out control surfaces but this is a fool proof way to get it done accurately with just hand tools.

In a couple of the picture you can see the markings for where the servo’s and hard points will go. Also, notice the extra cut line where about a one inch portion of the wing/aileron area will be removed to allow for the width of the balsa which will form the hinge & bevel areas. The shavings on the floor are from all the planning and shaping done on the leading and trailing edges.

[Fixed Wing]

The ailerons and elevators have now been cut and have had all leading trailing edges for the hinge lines cut, installed, and shaped. No pictures of this process. Let’s just say, I’m sick of shaping and sanding! Can you say, 96 fricken hinges with 192 hinge slots to cut? Everything was hinged using Dubro Heavy Duty Nylon hinges and piano wire so the control surfaces can be removed when desired.

I know there is some interest in how much these wings will ultimately weigh. These picture show actual weights for every thing except the Monokote. Looks like this wing with all servos, control horns, linkages, wiring, etc. but without Monokote weighs 48.9 ounces. I’m pleased with that.

[BoneDoc]

Excellent work there. Have you finish the build by now? How much does the plane weigh now as it sits?

Thanks
Josh

[Fixed Wing]

Wings and stabs are finally done with hard points, servo boxes, hinges, etc. all completed. Fuses are also pretty much complete except for cutting out the rearward canister vent areas. I know I’ll go ahead and cut out this area for the kit I’ll keep but I’m not real sure whether to go ahead and do it for the other kit. Whoever buys it may not want these cut outs if they run stock mufflers. Canopies and hatches have been glued, filled, pre-sanded and mounted. Next will come installation of the two piece cowls which will have cowl rings on both the top and bottom portions. After that comes the very tedious job of Monokoting.

[Fixed Wing]

Regarding the subject of weight. I went ahead and mounted the motor and canisters on kit #2 (the one I plan to keep). All remaining parts to complete the plane were then piled inside the fuse so an overall weight less Monokote could be determined. Just so you know the remaining parts included wheel pants, cowl baffle, ignition module, prop, 5”spinner, wheels, axels, 9 Hitec 5955 servos, choke servo, 2 Fromeco 4800’s, 1 Fromeco 2400, 3 switches, turbo regulator, ignition regulator, power expander, receiver, all control horns, all servo arms, all push rods, all wiring & extensions, fuel tank, fuel lines, filter, fuel dot, pilot figure, and various other hardware. It was a mess but it all was stuffed in there. Total all up weight less Monokote & paint was 36 pounds 1.2 ounces. I’m estimating about 22 ounces for Monokote & paint??? This would make a ready to fly weight with cans of about 37.5 pounds. This can be reduced even further by replacing the supplied aluminum wing tubes with carbon fiber.

Given these weights and knowing the additional things Jeremy has done to his Extra I would suspect that he really will get into the 36 pound ready to fly range.

[tonyedge540]

Must be catching doing this twin build !!! First one of these is on it's way for covering.
Engines will be ZDZ 160 Super's .

[Dangerous Dan]

Dean what did #1 weigh?

[Derek Hunter]

Looking good Tony

[Fixed Wing]

	Quote: Originally Posted by Dangerous Dan
	Dean what did #1 weigh?

Dan,

Extra #1 weighs 40 pounds & 4 ounces all up with cans. I didn't do much in the way of lightening. I have about 60 flights on it now and couldn't like it any better. It pulls very strong out of a hover and flies like its on rails. 40 Pounds for this plane is simply not an issue even for Unlimited but for some reason we all seem to be obsessed with making things lighter (that comment ought to cause some debate!). Even at 40 pounds, plane #1 will pull multiple snaps on the up-line without bleeding off significant speed.

Plane #2 will come in below 38 pounds with cans which is probably ideal for this size plane and IMAC. It looks like Plane #3 will be a tad bit heavier. I'm not real sure what is gained for going even lighter unless you're heavy into 3D and free style flying. Oops, another comment that will cause me some hate mail...

My real curiosity about these new planes relates to the design changes that John (Aerotech) has made to the wings and rudder. He has listened to Rathburn, Gonsoulin, and others and improved several things about an already great plane. You gotta respect companies who actually make improvements based upon customer feedback.

Dean