n00bs Gonna Build a Carden

[TrojanMan]

	Quote: Originally Posted by why_fly_high
	35% elephant maybe. Don't be hatin' you can't wear flip flops because of your nasty fungus toenails. Dan

That there is some Funny S#!t!



No hate'n here!

[gareth.ky]

The poly glue was setting up really slow this weekend. Still I got some work done:

Holes in the lower can tunnel area where sealed up with 3 layer balsa ply (3 layers of 1/32" glued together with poly glue).

The new firewall and extension block were cut and drilled. Everything was drilled at a 2.5 degree angle to match the right thrust provided by the SWB extension block. The back of the firewall was countersunk with a forstner bit so the T-nuts don't get twisted. The bolt heads and lock nuts will all sit flush so there are no pressure points. The design is basically the same as Walt's design on TBob's Yak.

Got the new foam parts sheeted and started putting then in place:

I bought a new tool, a spindle sander. This thing is bad to the bone! Its got a slot for a real man miter gauge and the dust collection is much better than the bench sander I had before.

[why_fly_high]

	Quote: Originally Posted by gareth.ky
	I bought a new tool, a spindle sander. This thing is bad to the bone! Its got a slot for a real man miter gauge and the dust collection is much better than the bench sander I had before.

I don't feel so bad about putting a flip flop through you turtledeck now. I loan you my tools, bandsaw and sander, and all you can do is complain about them.

Dan

[ben_beyer]

Hey gareth, are you just going to use standard mufflers on the 100?

[gareth.ky]

Yup. Thought about pipes but I can't afford it and I don't want the hassel.

[craig77]

Dude looking goooooooood

i'll be starting my 35% 260 very soon!have you guys seen my 40% vid??

[gareth.ky]

I made the belly pan this weekend and it is kind of cool. I've seen these angled chevron type slots cut in the bottom of composite airplanes and I wanted to do the same thing in Balsa. I didn't bother on the original because of the canister but that's never going back in.

A single piece of balsa would be too weak so I made up some balsa plywood. I measured to determine the thickness and I discovered that the foam belly parts highest point is 1/8" taller than the gear plate! To hide this I sanded the part so that it all blends together. To give myself enough material to sand away I made the top layer of the balsa ply 1/8" thick.

Cutting all those vents on the scroll saw would suck. Not to mention the total mess the scroll saw would make of the wood. This is what stopped me last time. So I got some MDF and made a template so I could sand them on the spindle sander.

I cut the ends with a Forstner bit and rough cut the edges on the scroll saw then cleaned it up on the spindle sander.

Here's how the first side went:

To made the other side you just flip the jig over. I'm happy with how it came out.

[ben_beyer]

Nice work!

[gareth.ky]

It was icy in Oklahoma last week. I took advantage and built a new freezer:

The firewall is on. I used some 3mm bolts to hold it in place because, like all plywood, it was a little bit warped. Clamping would have been hard and the bolts were easy. I also drilled a few lightening holes and capped them with some 1/8" balsa.

Doing a few other things. The tail gear plate had to go to build a new mount for the J&J Tailwheel. the T-nuts for the main gear were rusting so I'm replacing them with brass threaded inserts. the holes will get capped so fuel or whatever cant get in there again.

And now a question: The T-nuts in the wings, are bit loose. They got cross threaded and I tapped them back out. Any idea how I should fix this?

[flyin4fun]

Gareth,
Nice build, uhhhhhhhhhh or should I say rebuild
looks great !!

Doug

[gareth.ky]

I cant claim this as my own idea. Its actually two idea put together. I got my J&J tailweel and it came with these two plastic mounting brackets. They are kinda flimsy, I'm sure they work because I see lots of people using them, but they didn't strike me as sturdy. Also they were just too wide to use on a 35%. So then I saw this picture on the J&J site:

So I think that's a really clever idea but there are no pics of the inside. So I racked my bran for a week trying to decide how best to do the guts. The tailwheel exerts some serious shock forces on landing plus it exerts lateral forces when the airplane is sitting in the wind. I re-designed it in my head 6 different ways and none of them really worked well. I suffer from this perfectionist disease where I would rather not do anyhting that do something 1/2 way. So for a whole weekend I just didn't go out to the garage. Then I saw Dean's post:

Dean is a cool guy and he builds some really nice Carden's. I had the pleasure of meeting him at the SC regionals. This was apparently Rick Bird's idea and is going on his new Carden 300. I think they are onto something. The round block resists all forces equally. The nylon bushing comes from Ace Hardware and has an inner diameter of 0.257. That little 0.007 extra is just enough to make the 1/4" titanium wire easy to remove. So putting the two ideas together I made this:

No doubt its heavier than Dean's design. It does have than advantage that two of the bolts will help to hold the sheer block in place. The tailwheel isn't bent perfectly at 90 degrees, its about 1.5 degrees over. To get a smooth fit you have to drill the bushing hole with the drill press table slightly tilted to compensate. It could be lighter but overall I'm happy.

[TrojanMan]

Nice job Gareth!

Now get it done, we need you at 100% for the Tri State Shootout!