Composite-ARF 3M Yak 55 sp Build

[pepatrick]

You may want to reinforce the wood blocks that hold the canopy in...around the fuse. All 4 of mine have broken off at different times. I have heard of others having this problem too. I used aeropoxy and glued them back on. Then put an extra bead around the glue line that was already there blended it in. The epoxy with microballoons that they use is not as strong as aeropoxy..

[eagle1]

thanks for the info Pepatrick... I spoke with Ray about the cracking canopies and he told me that he has had good luck putting in a ply floor about an 1/8" from the bottom lip of the frame almost the full length of the canopy frame, I may do this as well, he agreed that the canopy needs to be made from thicker plastic
went to work on the ailerons to get them programmed in and before I could finish I did not order the right turnbuckles for the inside servos, I needed 3 1/2" and ordered 3", o' well gives mr time to get the servos screwed in the other wing and make the extensions for it.
other than that this plane is almost ready to go, I will not finalize the placement of batteries and rx's as I like using those to balance the plane out with instead of having to add extra weight.
I need to make the extensions for the elevators , I will only route the wire and put one end on for the elevators at the tail until I find out where I need the power box royal.
I am tired and will continue tomorrow, I may even carry it out side this weekend to get some good daylight pictures of the plane as well.

[pepatrick]

You know...for every $10.00 we miss when building these things...it seems to cost $100.00 to get it right. I have so many spare turn buckles and SWB / JR Servo arms that I should open up hobby shop. Its an addiction...its my crack!!!

[eagle1]

I knwo what you mean, with the spares I got I we can put them together and go in parters on a hobby shop..LOL

[eagle1]

I received the tracking number for my engine today, I also received the 32X10 mezlik prop.I should have the plane ready for the maiden flight by next weekend, I am still working on the one wing panel, trying to get the throw I want out of the aileron, i had to "dumb bell" the slots for the 4-40 ball links and sand the outer end of the wing sheet and the aileron, I also took 2mm off the skin on the bottom.

[eagle1]

I had my wing standing against the wall, root end up, mother-in-law called I've fallen and can't get up so we went over to her house to help her, while we were gone my cat desides to go play in my hobby room , knocked the wing over, hits on the flaired leading edge of the root end, knocks paint and filler offf both top and bottom of the wing, DA%IT!!!!!!
freackin cat I would like to kill the little Shi@ but I cannot,I'll shoot some pictures of the damage

[eagle1]

the past couple of days have been pretty productive, I have been able to get some of the smaller things done so when the motor comes in all I have to do is mount the 170, igition, and cans, then clear the kitchen to balance this bird, I will have to order the blue paint to get the "cat bite" off my leadong edge, i am going tot go ahead and fill in where the filler cracked off.
yesterday and to day I worked on getting the servos mounted in the other wing, making the extensions for the ailerons and the elevators.
I mounted the servo synchronizers in a place that will be easy to access if need be.
on routing the elevator extensions I had to put the exit holes behind the rear bulk head, I decided to run the extentions through a piece of fuel tubing to keep the carbon bulk head from rubbing a hole through the wire, I have found that a little 3 in 1 oil makes this job a little easier to get the three wires to go through the fuel tubing, otherwise you will not make it through an inch or so.
I need to fuel proof the firewall on both sides then all I can do is clean up the building table to get ready for the engine to arrive, Tru-Turn does not have the backplates for the DA-170 and are far behind, if they cannot get my backplate modified before tuesday they will ship me a 150 backplate and I will drill the holes myself.
I also added 18 grams of lead shot to the counter balance of the elevators and filled the holes with epoxy, micro ballons

[eagle1]

I recieved the last turnbuckles in, I proceeded to finish the linkages on the ailerons, program them and get them perfect, I have done that I think, one servo is giving me a little more buzz than what I like to hear, but the son is in bed, so I cannot refine that slot to make sure it is not the culprit,Done and Done,all that is left is tp balance the prop, mount the engine,cans and headers, make two extensions for ailerons,balance, first start, then the MAIDEN!!!!!!!
I appreciate all who have given me pointers during this installation, maybe one day I will do another true build to see if I can still build, I have not sheeted foam but I know I can do it, I just do not have a big enough band saw to make the cutouts.
Spinner should be here tomorrow or by wednseday,I will poilsh it then balance it when it comes in, look for a first start vid on Sat.

[pepatrick]

Looking good. I had a small mishap a landing a couple of weekends ago. I hit just a little too hard and the tail wheel flexed and went right up into the rudder. I am using a J&J tail wheel...and for reinforcement, I put a 1/4" brass tube in the hole for the tail wheel. This keeps it from flexing in the wood. I used Hysol to glue the brass tube in...The rudder was an easy fix, but I did a crappy job of painting it. I will probably have a buddy of mine respray it this winter.

Just finished installing the DA-170 today. I will take it out this weekend to see what kind power the motor has. Cant wait to try it out.

[eagle1]

pepatrick, where did you get your carbon for your baffle? that looks awesome, I cannot wait until I get the 170 here so I can get it installed and finish this plane, maybe we can both give our opinions at the same time, I will try to maiden mine on synday

[pepatrick]

I made the carbon fiber baffle. Here are the ingredients and directions.

1 or 2 2' x 2' piece of glass
Maguires mold release
4 cut up squares of carbon fiber cloth 18" x 18"
West Systems Epoxy slow harderner
small foam paint rollers from Home Depot
Wax paper

instruction to make

Use the Maquires mold release on the glass...I did it 5 times..it goes on like car wax and polishes off just like it too...
First layer of West Systems Epoxy... ( let it dry for several hours...You want it tacky..and try to get as many air bubbles out as you can).
First sheet of carbon cloth
more epoxy (keep it light)
2nd sheet of carbon cloth
more epoxy (keep it light)
3rd sheet of carbon cloth
more epoxy (keep it light)
4th sheet of carbon cloth
and again..more epoxy..but just enough to get it wet..

You apply the epoxy with the sponge rollers
You can also use a new sponge roller to soak up excess epoxy on the final layer of cloth. If you want both sides to have a mirror finish..its not a bad idea to have a little more epoxy on the last layer of cloth..

now...2 options..you can have the front side mirror finish and the back side rough (this is how mine is) or both sides mirror finish...this requires a litte more work...

Option 1. Put a sheet of wax paper of the last layer of cloth...then lay a flat piece of really smooth wood or glass on top of the wax paper...lay a 50 pound bag of sand on top of it..all night...

Option 2. get another piece of 2' x 2' glass...use the maguires mold release on it...a small layer of west epoxy and let is set up a few hours to get tacky and then set that on top of the last layer of carbon cloth...and add the 50 pound bag of sand on top...

Its sounds like a lot of work..but it really is not that bad. It is very strong...very light...and the bugs scrape off of very easily...especially if you wax the baffle every once in a while.

[eagle1]

where do you get your carbon? I have looks at some but all I have found is laminate

[eagle1]

After what? 3 or 4 days of playing with the programming the aileron servos I finally got it right!
everytime I thought I had it something would change, don't know if it was me or the electronics and me or just me, but I have it under control and things are looking great, maybe one of the best jobs I have done.
I received the 5" P-51 spinner in today, looks great in front of the plane, I cannot wait until friday to get the engine mounted and finish this bird so I can get the plane in the air. this weekend will tell all, throws look good and I think this will be a monster...!!!can't wait

[pepatrick]

I got this from Jamestown distributors...same place I get the West Epoxy...I just looked on their website and did not see the stuff I bought...Other people that have done this found it on e-bay...I think it 2.5 oz cloth..I bought it about a 1.5 years ago..

	Quote: Originally Posted by eagle1
	where do you get your carbon? I have looks at some but all I have found is laminate

[eagle1]

I sanded the turning marks off the spinner the polished, this is one of the brightest poilsh jobs I have done