Pieter Visser

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Re: Pieter Visser

Postby Pieter001 » Sun Apr 26, 2015 9:47 pm

I'll have to upload some pics, but I did get some work done...

Cut all the glass for the main gear's last step. I used 410gr, so a few less cuts, but it still took a good while.

Then, while cutting, decided to cut the 400gr +/-45 carbon I want to use to build a new rudder shear web. After cutting I lay an old glass roof panel on the dining room table (wife approved if only for a day...) and polished it up. I then did the layup for the shear web. I have to say, I LOVE working with the carbon, apart from cutting it, the layup work and everything else around it is fantastic. I can however understand that it will not drape nearly as easily as the glass does, as it is really stiff!

Will post some pic... Keen to see if what I've laid up is stronger than the original, or if I'll have to add another layer or two. The idea is to save weight, and I don't doubt that in this part alone I've shaved off a huge amount of weight!

20150426_115457.jpg
Cutting Main Gear last step glass, finally
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20150426_195020.jpg
New Carbon Rudder Shear web
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Rudder shear web layup: 400gr +/-45 biax of medium modus - Final layup, which works best in my opinion...

Peelply

1 layer 180 X 1420

3 layers 120 x 120 (top hinge)

1 layer 180 X 1420

3 layers 120 x 120 (bottom hinge)

1 layer 180 x 1150 (80% of overall length, started at the bottom)

3 layers 180 x 120 (bottom horn area)

1 layer 180 x 800 (56% starting at the bottom)

1 layer 180 x 400 (28% starting at the bottom to cover rudder horn and bottom hinge)

1 layer 180 x 1420

Peelply
Last edited by Pieter001 on Mon May 04, 2015 1:13 pm, edited 1 time in total.
Pieter001
 
Posts: 162
Joined: Wed Jul 03, 2013 7:03 pm
Location: Heidelberg GP

Re: Pieter Visser

Postby Pieter001 » Wed Apr 29, 2015 7:56 pm

I weighed the rudder shear web and it came to 1200gr!

The original part is 1500gr, so not a big saving, not what I had hoped or expected.

That said, the carbon shear web is MUCH stiffer than the glass, I believe maybe a tad over engineered... As weight at the rudder, because of its moment arm, has the most impact on CoG, I wish to make this part as light as possible, but not discarding any safety factors in doing so.

I'm thinking of leaving out the last layer of 180 x 1420, so that where I finished with 2 layers, to only finish with 1. This should shave off around 200gr at least, leaving the shear web at around 1000gr, more what I had hoped for.

I also got new polystyrene today, with which I plan to cut a new rudder. This time I'll remove excess foam from the cores. The idea is to cut the core in half and then remove sections from the inside and thereafter gluing them back together for covering. I guess one should save at least 200gr (maybe a little more ;)) in doing this. I'll also be covering the rudder in carbon, the layup still needs to be finalised, but I expect to save around 30% of the weight when compared to fiber glass covering.

All this should then also have a positive influence on the counter balance weight, reducing the weight required, but time will tell...
Pieter001
 
Posts: 162
Joined: Wed Jul 03, 2013 7:03 pm
Location: Heidelberg GP

Re: Pieter Visser

Postby Pieter001 » Mon May 04, 2015 1:25 pm

I made another rudder shear web, using the layup described above. It came to just over 1000gr, so I'm happy :D

I've also made formers to remove excess foam from the rudder leading edge. I removed around 105gr of from just from the rudder leading edge! The main rudder should shave off at least another 200gr I'd guess.

If all goes well I'll be cutting the new rudder this week and then make the formers to remove excess foam from the rudder core, so I'll update with progress...

20150501_171439.jpg
Rudder leading edge foam removed and formers used
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20150501_171551.jpg
Core sections micro'd back for support on hinge etc
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20150501_184354.jpg
Around 105gr of foam removed in the end
20150501_184354.jpg (167.65 KiB) Viewed 2467 times
Pieter001
 
Posts: 162
Joined: Wed Jul 03, 2013 7:03 pm
Location: Heidelberg GP

Re: Pieter Visser

Postby Brett » Mon May 04, 2015 7:48 pm

Looking good Pieter. I picked up my new carbon fibre ailerons from Russell on Saturday and must say they look very nice.
Brett
 
Posts: 39
Joined: Fri Nov 02, 2012 9:10 pm

Re: Pieter Visser

Postby Pieter001 » Tue May 05, 2015 10:00 am

Hi Brett,

Thank you.

I'm certainly going the carbon aileron route too. I wish PE was not so far away!!

How are you progessing?

Rgds,

Pieter
Pieter001
 
Posts: 162
Joined: Wed Jul 03, 2013 7:03 pm
Location: Heidelberg GP

Re: Pieter Visser

Postby Brett » Sun May 10, 2015 8:31 am

Hi Pieter

I started building the rudder this weekend. We attached the foam to the shear web and will do the glass next weekend. I have also now aligned and attached the horizontal stab. I am going to assemble the stab control mechanism and then cut out the elevators. I am almost done with the major airframe components. It will be aileron and flap fitment after this and then the canopy.

As Russell says, one small bite at a time!

Regards
Brett
Brett
 
Posts: 39
Joined: Fri Nov 02, 2012 9:10 pm

Re: Pieter Visser

Postby Pieter001 » Mon May 11, 2015 3:25 pm

Hi Brett,

Excellent :D

I'm also working on the rudder, as can be guessed. If all goes well, I should also look at skinning over the next 2 weeks. I'm out of resin and hardener, so I need to go and get some this week.

Best of luck, post some pics, would love to see your work :D

Pieter
Pieter001
 
Posts: 162
Joined: Wed Jul 03, 2013 7:03 pm
Location: Heidelberg GP

Re: Pieter Visser

Postby Pieter001 » Fri May 15, 2015 8:52 am

I've cut a new rudder from EPS. I then bonded the 2 halves in the cradles from which they were cut, so I got a 100% perfect lineup. Thereafter I decided to cut the rudder on the shear web line, but in 1 long cut over both joined halves. I found my first rudder was very slightly out (little banana shaped) as I cut the 2 halves separately and the 1mm or so I was out here, resulted in the outer ends of the rudder not touching the flat surface if I laid it on its "face". For this I needed a long bow hot wire cutter, easily made. However, the wire did not get hot enough for a nice cut over the 1.45m length! Thus, the cut was made, but painfully slowly. Alas, it is 100% perfect this time :D

I then trimmed out excess foam, as before, but left more in the hinge and horn sections. At these sections more foam will be removed to accommodate the hinges, so the weight will be reduced later. I marked the hinge positions and I also shaped the rounding of the rudder based on the shear web rounding for which I used a compass to get the circle perfect.

Now, cutting the hinge sections... Russell used a wire brush on a drill, which is great, but I do not trust my ability to do this well, so I'm going to hot wire cut based on a template (freehand and risky!!). I'll error on the safe side and there after I'll sand it down as required. My idea is then to micro this section and leave it clean for painting.

20150514_180635.jpg
Bottom of EPS rudder leading edge shaped according to the shear web
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20150514_182129.jpg
Hinge positions marked
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Pieter001
 
Posts: 162
Joined: Wed Jul 03, 2013 7:03 pm
Location: Heidelberg GP

Re: Pieter Visser

Postby Pieter001 » Mon May 18, 2015 7:27 am

Used permanent lock tight with the nyloc nuts to permanently fix the hinges and control horn to the rudder shear web. Used s/steel cap screws: 5mm for top hinge and 6mm for everything else. Had to drill the holes on the control horn and ream the hinges slightly to fit the 6mm. The horn is seriously hard metal and it was difficult to get this drilled using a cheap 6mm drill bit.
I then glued the EPS leading edge to the shear web, but putting the leading edge in its cradle and then weighting the shear web down on top of it. Worked great!

20150517_172437.jpg
Hinges and horn permanently fixed to shear web
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20150517_174200.jpg
Cut cradle to accommodate rudder horn
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20150517_181625.jpg
Weighted shear web down on the EPS leading edge in cradle while gluing
20150517_181625.jpg (167.29 KiB) Viewed 2371 times
Pieter001
 
Posts: 162
Joined: Wed Jul 03, 2013 7:03 pm
Location: Heidelberg GP

Re: Pieter Visser

Postby Pieter001 » Mon May 18, 2015 7:36 am

Just a picture of the completed shear web.

Will now be fitting this to the tail on the plane and trim the skins on the Vstab as need to get a good fit.

I'm not sure how I'm going to get access to the lower rudder hinge to tighten and cotter pin the castle nut on the hinge, while fitted :?:

There will be a way... :idea:

20150518_055452.jpg
Completed EPS leading edge bonded to shear web
20150518_055452.jpg (152.43 KiB) Viewed 2371 times
Pieter001
 
Posts: 162
Joined: Wed Jul 03, 2013 7:03 pm
Location: Heidelberg GP

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