Ziroli 92" p-47 build thread
07-11-2015, 11:19 AM
#51
Wings (cont)
Left wing (cont)
Some of Brian's clear template plastic used to make a flap template.
Some 1/64" thick ply CA'ed to the TE of the flap to nearly make it impervious to warping, able to sand to a scale contour and limit hanger rash.
Ditto for the aileron.
Flap and aileron glued to the wing ribs.
Half of the LE left for the LE sheeting.
Left wing (cont)
Some of Brian's clear template plastic used to make a flap template.
Some 1/64" thick ply CA'ed to the TE of the flap to nearly make it impervious to warping, able to sand to a scale contour and limit hanger rash.
Ditto for the aileron.
Flap and aileron glued to the wing ribs.
Half of the LE left for the LE sheeting.
Last edited by samparfitt; 07-11-2015 at 11:21 AM.
07-12-2015, 07:25 AM
#53
Wings (cont)
Seemed like a good time to epoxy the two wings together.
After that cured, the front/back ply spars were glued in.
Some balsa blocks were installed under the front/back wing bolt ply plates for bolt guides.
The TE spar was made from aircraft ply to keep the wing from twisting.
Made notes in the wing so I don't forget anything!
Seemed like a good time to epoxy the two wings together.
After that cured, the front/back ply spars were glued in.
Some balsa blocks were installed under the front/back wing bolt ply plates for bolt guides.
The TE spar was made from aircraft ply to keep the wing from twisting.
Made notes in the wing so I don't forget anything!
Last edited by samparfitt; 07-12-2015 at 07:30 AM.
07-14-2015, 11:38 AM
#58
Thanks, Scott.
Been unusual weather here in SW Ohio for the last month, 70's/low 80's with rain just about every day for the last 4 weeks.
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Wing (cont)
Flaps (cont)
Glued in the end flap ribs (W-3G/8G).
Hinges:
Using G10 hinges. One 1/8" thick on the flap side and two 1/16" thick on the wing side with a 1/8" thick ply sandwiched between the two 1/16" G10's. 4/40 bolts and locking nuts for the pins.
Took several hours to cut all eleven pieces. Even with 30 minute epoxy, only one batch of epoxy per hinge setup with 11 pieces to glue and assembly.
Easiest for alignment leaving the flaps attached to the wing while installing all the hinges. Critical to get all 4/40 bolts aligned along the LE of the flaps.
Been unusual weather here in SW Ohio for the last month, 70's/low 80's with rain just about every day for the last 4 weeks.
=======================
Wing (cont)
Flaps (cont)
Glued in the end flap ribs (W-3G/8G).
Hinges:
Using G10 hinges. One 1/8" thick on the flap side and two 1/16" thick on the wing side with a 1/8" thick ply sandwiched between the two 1/16" G10's. 4/40 bolts and locking nuts for the pins.
Took several hours to cut all eleven pieces. Even with 30 minute epoxy, only one batch of epoxy per hinge setup with 11 pieces to glue and assembly.
Easiest for alignment leaving the flaps attached to the wing while installing all the hinges. Critical to get all 4/40 bolts aligned along the LE of the flaps.
Last edited by samparfitt; 07-14-2015 at 11:43 AM.
07-15-2015, 06:27 AM
#61
Thanks, Ragtop,
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Wing (cont)
Ailerons (cont)
Cut the ailerons off the wing and sanded the LE of the ailerons and TE of the wing.
Glued 1/8" thick balsa sheet to the LE of the ailerons and TE of the wing.
Flaps (cont)
LE of the flap ribs rounded in prep for sheeting.
Water added to the outside surface of the 3/32" thick balsa sheet and glued to the LE of the flaps.
==========
Wing (cont)
Ailerons (cont)
Cut the ailerons off the wing and sanded the LE of the ailerons and TE of the wing.
Glued 1/8" thick balsa sheet to the LE of the ailerons and TE of the wing.
Flaps (cont)
LE of the flap ribs rounded in prep for sheeting.
Water added to the outside surface of the 3/32" thick balsa sheet and glued to the LE of the flaps.
07-15-2015, 01:13 PM
#62
Wing (cont)
Flaps/ailerons:
Sanded the LE's of flaps and ailerons. Put some masking tape along the top surface of the ailerons to sand the acute angle LE while not damaging the top sheeting.
Used a dremel drum sander to contour the TE of the wing by the flaps.
Next, hard points for the aileron hinges.
Called Darrell, last week, and got some new wheels and they just came in.
The new ones have 4" rims versus the old 3" with the real wide tire.
The new ones are also thinner, width wise.
Flaps/ailerons:
Sanded the LE's of flaps and ailerons. Put some masking tape along the top surface of the ailerons to sand the acute angle LE while not damaging the top sheeting.
Used a dremel drum sander to contour the TE of the wing by the flaps.
Next, hard points for the aileron hinges.
Called Darrell, last week, and got some new wheels and they just came in.
The new ones have 4" rims versus the old 3" with the real wide tire.
The new ones are also thinner, width wise.
Last edited by samparfitt; 07-15-2015 at 01:15 PM.
07-16-2015, 05:01 AM
#63
Wing (cont)
Ailerons (cont)
Balsa block used for hardpoints in wing and ailerons.
Dubro heavy duty nylon hinges are used.
Slot for hinge is about an 1/8" from top surface and cut at about a 45 degree angle to get to the meat of the hardpoint and also puts the hinge pin at surface level.
Xacto saw blade used to make slot.
Due to curve of outer aileron, that hinge is moved inward.
Some easysand bondo to fill in gap between top sheet and LE.
Ailerons (cont)
Balsa block used for hardpoints in wing and ailerons.
Dubro heavy duty nylon hinges are used.
Slot for hinge is about an 1/8" from top surface and cut at about a 45 degree angle to get to the meat of the hardpoint and also puts the hinge pin at surface level.
Xacto saw blade used to make slot.
Due to curve of outer aileron, that hinge is moved inward.
Some easysand bondo to fill in gap between top sheet and LE.
Last edited by samparfitt; 07-16-2015 at 05:12 AM.
07-28-2015, 11:55 AM
#71
Wing (cont)
Receiver:
Copied the 110" P-47 over to the 96" to save set up time and binded the receiver.
Flaps (cont)
Some homemade servo trays for HS-645's.
Flap 1/8" thick aircraft ply control horn sandwiched between two 1/8" thick balsa ribs.
TE spar and triangle stock of wing needed trimming for arm clearance.
Hardwood 1/4" square back and 1/4"X1/2" front with 1/8" thick ply for shelf to mount servo tray.
50 degrees put into flaps with servo straight back. 4/40 ball links and 3rd hold is used on servo arm for max torque and 90 degree movement.
Receiver:
Copied the 110" P-47 over to the 96" to save set up time and binded the receiver.
Flaps (cont)
Some homemade servo trays for HS-645's.
Flap 1/8" thick aircraft ply control horn sandwiched between two 1/8" thick balsa ribs.
TE spar and triangle stock of wing needed trimming for arm clearance.
Hardwood 1/4" square back and 1/4"X1/2" front with 1/8" thick ply for shelf to mount servo tray.
50 degrees put into flaps with servo straight back. 4/40 ball links and 3rd hold is used on servo arm for max torque and 90 degree movement.
Last edited by samparfitt; 07-28-2015 at 12:03 PM.
08-01-2015, 12:12 PM
#72
Wing (cont)
Flaps:
Boxed in the flap hatch with 1/4 square basswood for the cover and balsa for the wing sheeting support.
Ailerons.
Ditto for boxing in the aileron hatch.
Some homemade servo supports from 1/8" thick L angle aluminum stock, drilled/tapped 2/56 screws for servo hole support and 4/40 screws for L angle to 3/32" thick aircraft ply hatch cover. Some heavy duty 4/40 ball links on the servo side and robarts 4/40 ball control horns on the aileron side using servo hex head screws to secure the control arm to the 3/32" thick aircraft ply plate. The plyplate was glued over the aileron's LE and ribs so the bottom balsa sheeting will be flush with the ply plate. In the past, I have put the balsa sheeting over the ply plate but the control horn can crush the balsa sheeting, even after fiber glassing.
Flaps:
Boxed in the flap hatch with 1/4 square basswood for the cover and balsa for the wing sheeting support.
Ailerons.
Ditto for boxing in the aileron hatch.
Some homemade servo supports from 1/8" thick L angle aluminum stock, drilled/tapped 2/56 screws for servo hole support and 4/40 screws for L angle to 3/32" thick aircraft ply hatch cover. Some heavy duty 4/40 ball links on the servo side and robarts 4/40 ball control horns on the aileron side using servo hex head screws to secure the control arm to the 3/32" thick aircraft ply plate. The plyplate was glued over the aileron's LE and ribs so the bottom balsa sheeting will be flush with the ply plate. In the past, I have put the balsa sheeting over the ply plate but the control horn can crush the balsa sheeting, even after fiber glassing.
Last edited by samparfitt; 08-01-2015 at 12:18 PM.
08-03-2015, 05:43 AM
#73
Hay Sam I did something similar to what you are doing to my seafury for the wing flaps works very well but I found that the servos have to be laying in the same direction
Jim
Jim
