Toronto Electric Model Aviation Club Forum

Toronto Electric Model Aviation Club (TEMAC) => Building / Construction => Topic started by: Frank v B on May 13, 2018, 09:56:11 AM

Title: Frank's Rainbow 2000 (.45-.55 size) build
Post by: Frank v B on May 13, 2018, 09:56:11 AM
John's Hobbies asked me to assemble a plane for a customer.  This post will cover all the assembly steps and the reinforcing details.  This plane is for .46-.55 size motors but the Customer wants an E-Flite .60. Remember the advice: "Always overpower an airplane.  You can always throttle back.... if you have to". There will probably be a fair amount of reinforcing around the motor box and the wing mount.

Details:
- Rainbow 2000 1/5 scale ARF by PhoenixModel.  It looks a bit like a mid-air fusion of a Taylorcraft and a Sig Cadet Senior.
http://phoenixmodel.com/Product.aspx?ProductId=595
- 78" span, 61" length
- 4 channel set-up with individual aileron servos
- 8 lbs
- E-flite .60 on 8S 3200 16 x 8 APC E prop
- ESC- not chosen yet.

Gentlemen, start your insults.  ;D
When I retrieve (find) my camera in my car I will charge the batteries first and post a photo.  That will start Andy's critique of my (non-existent) photography skills.  It will start Bruce's helpful posts like "The rudder goes on the back end Frank", and the normal abuse from the Morning Crew.

Looking forward to it.  If this is "work", give me more!!! 8)


Frank
Title: Re: Frank's Rainbow 2000 (.45-.55 size) build
Post by: Frank v B on May 13, 2018, 11:18:55 AM
Gentlemen, start your insults! :)

Opening the box:
All the parts wrapped in plastic, small parts bagged, cowl wrapped in protective foam.
Photo 33- the outside of the box
Photo 34- the inside of the box
Photo 35- the fuse, wing tubes and small parts bag.
Photo 36- transparent covering shows the part numbers.  I checked the wings, the balsa under the covering does not say "Left wing, stupid!"
Photo 37- This weird device was found in the box.  Looks like some alien pill bottle.  Will have to research its purpose. ;D ;)

Frank

ps: Andy, sorry about the glare in photos 34 and 35. :D  PhotoShop does not live here. ;)

Title: Re: Frank's Rainbow 2000 (.45-.55 size) build
Post by: Frank v B on May 13, 2018, 10:28:09 PM
Started with the fuselage, opposite to the instructions.  A fuselage is easier to tinker with when there is nothing attached to it.  While working on the nose, the plastic bag surrounding the fuse was left in place.

Attached the plywood E-motor mount on the stand-offs per the instructions.  When I saw the motor was larger, I added washers on the bottom of the stand-offs where they touched the plywood firewall.  This was done just to spread the load over a greater area.  See photo 38

Problem: remember the .60 size motor I outlined in the first post.  It was a Power 90!!!  Holy crap!

Step 1- the X-mount was larger than the width of the firewall.  Found a smaller 46-60 E-Flite X-mount kit.  This created a new problem.  The mount holes were too close to the motor housing so they had to be elongated.  See photo 42.  On the right is the mount that came with the motor, on the left is the new smaller one with elongated mount holes.

Step 2- remove the T nuts from the motor mount so new holes can be drilled.  Removing the T-nuts was easy.  Insert the 4 screws into the T-nuts (see before photo 39) and one light tap of a hammer and they came out cleanly (see photo 41).  Photo 43 shows the 4 T-Nuts dropped down.

Step 3 is tomorrow.  Drilling the new holes for the new T-nuts.
Title: Re: Frank's Rainbow 2000 (.45-.55 size) build
Post by: Frank v B on May 15, 2018, 10:36:25 PM
Now to fit the motor to the firewall.  problems:
1) the smaller "X"mount needed to have the holes elongated.
2) one of the screws to hold the firewall in place was always in the way.
3) Some of the hold down screws were getting close to the edge of the plywood

Solution-
- used one of the firewall bolts as one of the four bolts to hold down the motor.  This bolt had to have the head tapered so it would clear the stationary part of the motor. The head of the bolt was tapered by holding it to the grinder. Photos 1747, 1748 and 1749
- removed all of the T nuts and sanded the back of the plywood motor mount.  photo 1750
- glued the motor mount to a larger piece of plywood so the part holding the T-nuts was larger.  Used 5 minute epoxy and glued and clamped it.  Will let it cure overnight and then pass it through the band saw.  Photo 1751

Note: I plan to attach the motor "as is" to the front of the plane.  Because the motor is larger (longer) and the plywood is thicker, the motor will probably be too far forward.  When the cowl is first slipped on, the metal stand-offs (posts) will be cut by the correct amount to put the prop in the correct place.  No need to worry about it now.

Frank



Title: Re: Frank's Rainbow 2000 (.45-.55 size) build
Post by: piker on May 16, 2018, 02:21:52 PM
I was wondering about 6 cells on an E-Flite 60.  Then I saw the "90" comment.  Um.  Ya.  That's a lot of power for that plane.  Better reinforce the wings along with the nose... and maybe the tail surfaces too   :o
Title: Re: Frank's Rainbow 2000 (.45-.55 size) build
Post by: Frank v B on May 16, 2018, 10:51:44 PM
Piker,
I will definitely be looking at the strength of the tail feathers.  My advice would be to not prop for full power but economical power (lower pitch prop).  The nice thing about the 90 is that it is heavier. The .90 weighs 15.8 oz, 2.4 oz heavier than the .60.  Cabin planes tend to be tail heavy.  Also, it is much safer to fly with the CG further forward.

Finishing the firewall.
- Cut the new firewall on the band saw.  Photo 52 shows the firewall from the front with the old .46-.55 holes.  You can see the new firewall piece sticking out all 4 sides at the back.
- Photo 53 shows the back of the firewall with the firewall mounting holes (plain holes) and the motor mount holes with the 3 T nuts in place.  The bottom hole with the arrow is the firewall mount screw that is doing double duty as a motor mount screw as well.

Didn't get a chance to do much more because tonight was training night.  My instructor Bruce said I did well. ;D ;) ;D ;)

Frank
Title: Re: Frank's Rainbow 2000 (.45-.55 size) build
Post by: Frank v B on May 17, 2018, 11:00:34 PM
Got back at it tonight and installed the motor.  Everything fits now and can be tightened.  The aluminum stand-offs will probably have to be trimmed but I will wait to do that at the cowl stage.

There was a lot of fiddling because the motor mount screws just cleared the Xmount.  In two places I had to reduce the size of the washers so they would not interfere..... but it is now done.  In the photos you can clearly see the firewall in now almost twice as thick.

Installed the aileron hinges in the starboard wing.

The detail work (covering, glue joints, etc.) on this plane is superb.

Frank
Title: Re: Frank's Rainbow 2000 (.45-.55 size) build
Post by: bweaver on May 17, 2018, 11:16:17 PM
I  hope that 5 minute epoxy set before you moved on...  Took two nights this time?  Sleep tight Frank.  ;)
Title: Re: Frank's Rainbow 2000 (.45-.55 size) build
Post by: Frank v B on May 18, 2018, 04:32:42 AM
Bruce:

re: your "Took two nights this time?" 

Yep.  576 "5 minutes" later.  That's what happens when you don't push the start button on your 5 minute timer. ;)

Frank
Title: Re: Frank's Rainbow 2000 (.45-.55 size) build
Post by: bweaver on May 18, 2018, 08:28:56 AM
Frank:

re: That's what happens when you don't push the start button on your 5 minute timer.

Or in your case, you likely did set it. The alarm did go off. You hit the snooze button, only to wake up two days later to find you are in the land of Lilliput, where washing machine motors are installed on the front of electric model airplanes...    ;D

Great instructions by the way on how to mount such motors.
Title: Re: Frank's Rainbow 2000 (.45-.55 size) build
Post by: Frank v B on May 18, 2018, 10:39:13 PM
Bruce,

re: "Great instructions by the way on how to mount such motors."

Do you realize that was a compliment??  Are you feeling OK?  Sunburn ?  Windburn? Alzheimers?  Just plain old age? ;D

Today's progress:

Servo rails- I always hate the servo rails in ARF's.  They are usually lite ply, they split and are generally light.  Installed plywood doublers underneath where the servo screws were to go.  Cut two pieces of plywood (photo 1757) and drilled servo holes in the original servo rails.  Applied glue (5-minute) to the plywood doublers and used the servo screws as clamps (photo  1758).

Landing gear- this kit comes with two sets of wheels.  Smaller wheels for use with wheel pants and larger wheels for grass flying.  Made the smaller wheels because this way they can be switched back and forth.  The wheel pants were fiddly and needed to be drilled and fitted. Photos 1761 and 1762.

Hinged the second wing half as well.  Both wings are now done.

Frank

Title: Re: Frank's Rainbow 2000 (.45-.55 size) build
Post by: Frank v B on May 19, 2018, 10:53:04 PM
No photos today because I am prepping to go for my first casual flying session of the year tomorrow morning. Gotta get there early before the leaf blowers arrive.  :D Re-scheduled Jets Day. :)

Done today:
Increased battery space- the owner wanted more room for bigger batteries.  The pilot (full body) was in the way.  Could not break it from the seat and could not break the seat from the bottom of the fuse without splintering some wood.  The plane now has a paraplegic pilot.  Broke the legs off at the hip.  This pilot was made in pieces. More leg room for the battery.

Reinforce the firewall- applied 20 minute epoxy (don't wake up Bruce!) with a brush to the area where the firewall meets the fuselage sides.  Applied a piece of fibreglass (2-3 oz weight) cloth to the epoxy and then brushed on some more epoxy to work out air bubbles.  Applied pieces of waxed paper on top so I could squeeze the air out of the cloth.  The waxed paper forces all the fibres flat while the epoxy cures.  Tomorrow I will remove the waxed paper and will not have to sand it smooth.

Frank
Title: Re: Frank's Rainbow 2000 (.45-.55 size) build
Post by: bweaver on May 19, 2018, 11:34:59 PM
Frank, re - "...applied 20 minute epoxy (don't wake up Bruce!) with a brush to the area where the firewall meets the fuselage sides."

You did wake me up!  I new you would be mixing epoxy again.  Except now you are using 20 minute epoxy to justify the extended curing time? Or was that it that it would take you 15 minutes to get the bubbles out of cloth and waxed paper before the epoxy naturally cures and you can't do no more?   

Now I think I'm understanding your approach to the use of epoxy and allowing for the unnecessary cure rate time.  First you mix and apply the epoxy.  You take time now with 20 minute epoxy to spread it evenly, get the air out of the glass cloth and from under the waxed paper. Then you go to bed assuming everything is hunky-dory (get a good nights sleep for fear that if you made a mistake and found it earlier...), so that you can be excited when you peel back the waxed paper hoping that it is so smooth, you don't have to sand it. 

I might try that sometime, but I don't think I have the patience.  :-*
Title: Re: Frank's Rainbow 2000 (.45-.55 size) build
Post by: Frank v B on May 21, 2018, 09:28:42 PM
Just to tick Bruce off.... just finished some more fibreglassing with 20 minute epoxy.  He is going to be soooo confused.

- finished fibreglassing the firewall. Applied pieces of fibreglass with 20 minute epoxy and covered them with waxed paper.  The entire firewall is now glassed from the upper part of the fuse side all the way around the bottom and up the other side.

- Glassed the landing gear mount.  Removed the pilot's legs and half the battery tray to get at the landing gear mount.  ARFs with a small plywood plate always have the mounts knocked off in harder than normal landings.  The landing gear becomes a lever and pries the mounting plate loose.  To avoid this, I put fibreglass at the back and the front of the plate to triple the length of the plate.  This spreads the land over a much larger area.  Oh, yes, covered it with waxed paper.

Let it dry overnight.  Or as Bruce would understand, 68 mixes of 20 minute epoxy (23 hours) until I get home tomorrow.

Frank

Title: Re: Frank's Rainbow 2000 (.45-.55 size) build
Post by: Frank v B on May 22, 2018, 10:18:48 PM
Here are the photos:

- gone are the pilot's legs.  More room for the batteries.  Photo 82

- the nose as viewed from the open hatch.  The right half of the photo behind the firewall is fully glassed.  The left half of the hatch is the glass reinforcement for the landing gear block.  Below the plane is the balsa battery tray.  I cut this half away to access the the landing gear blocks.  The pilot would not budge so I had to leave him in place.  Photo 81

- the cockpit showing the extra room now that the legs are gone.  The main former in front of the pilot has glass in the bottom to strengthen the aft portion of the landing gear block.  Photo 80.

Frank

Title: Re: Frank's Rainbow 2000 (.45-.55 size) build
Post by: Andy Hoffer on May 22, 2018, 11:08:15 PM
Quote from: Frank v B on May 13, 2018, 10:28:09 PM
Started with the fuselage, opposite to the instructions.  A fuselage is easier to tinker with when there is nothing attached to it.  While working on the nose, the plastic bag surrounding the fuse was left in place.

Attached the plywood E-motor mount on the stand-offs per the instructions.  When I saw the motor was larger, I added washers on the bottom of the stand-offs where they touched the plywood firewall.  This was done just to spread the load over a greater area.  See photo 38

Problem: remember the .60 size motor I outlined in the first post.  It was a Power 90!!!  Holy crap!

Step 1- the X-mount was larger than the width of the firewall.  Found a smaller 46-60 E-Flite X-mount kit.  This created a new problem.  The mount holes were too close to the motor housing so they had to be elongated.  See photo 42.  On the right is the mount that came with the motor, on the left is the new smaller one with elongated mount holes.

Step 2- remove the T nuts from the motor mount so new holes can be drilled.  Removing the T-nuts was easy.  Insert the 4 screws into the T-nuts (see before photo 39) and one light tap of a hammer and they came out cleanly (see photo 41).  Photo 43 shows the 4 T-Nuts dropped down.

Step 3 is tomorrow.  Drilling the new holes for the new T-nuts.

Photo 43 also shows the effects of @Frank v B  taking photos with out his glasses on !!  8)

Andy
Title: Re: Frank's Rainbow 2000 (.45-.55 size) build
Post by: Andy Hoffer on May 22, 2018, 11:15:12 PM
Quote from: Frank v B on May 22, 2018, 10:18:48 PM
Here are the photos:

- gone are the pilot's legs.  More room for the batteries.  Photo 82

- the nose as viewed from the open hatch.  The right half of the photo behind the firewall is fully glassed.  The left half of the hatch is the glass reinforcement for the landing gear block.  Below the plane is the balsa battery tray.  I cut this half away to access the the landing gear blocks.  The pilot would not budge so I had to leave him in place.  Photo 81

- the cockpit showing the extra room now that the legs are gone.  The main former in front of the pilot has glass in the bottom to strengthen the aft portion of the landing gear block.  Photo 80.

Frank

Perhaps @Frank v B can explain how the pilot will reach the rudder pedals without his legs!!   8)

Andy
Title: Re: Frank's Rainbow 2000 (.45-.55 size) build
Post by: Frank v B on May 24, 2018, 11:32:07 PM
Andy: re: how the pilot will reach the rudder pedals without his legs!!   8)

Rudder is over rated.  Half my planes don't have one.  Who needs legs anyways.  Hand controls.  Use your imagination.

Frank

ps: Andy, thanks for picking out the spelling mistake.
Title: Re: Frank's Rainbow 2000 (.45-.55 size) build
Post by: Andy Hoffer on May 25, 2018, 12:06:15 AM
Quote from: Frank v B on May 24, 2018, 11:32:07 PM
Andy: re: how the pilot will reach the rudder pedals without his legs!!   8)

Rudder is over rated.  Half my planes don't have one.  Who needs legs anyways.  Hand controls.  Use your imagination.

Frank

I trust you realize that this is a very dangerous proposition!   8)

Andy
Title: Re: Frank's Rainbow 2000 (.45-.55 size) build
Post by: piker on May 25, 2018, 11:41:21 AM
Quote from: Frank v B on May 24, 2018, 11:32:07 PM
Andy: re: how the pilot will reach the rudder pedals without his legs!!   8)

Rudder is over rated.  Half my planes don't have one. 

Most of your planes don't have wheels... but I guess if most of your landings are nose first in the mud, or upside down on the runway, wheels are over rated too   ;D
Title: Re: Frank's Rainbow 2000 (.45-.55 size) build
Post by: Andy Hoffer on May 25, 2018, 06:32:16 PM
Quote from: piker on May 25, 2018, 11:41:21 AM
Quote from: Frank v B on May 24, 2018, 11:32:07 PM
Andy: re: how the pilot will reach the rudder pedals without his legs!!   8)

Rudder is over rated.  Half my planes don't have one. 

Most of your planes don't have wheels... but I guess if most of your landings are nose first in the mud, or upside down on the runway, wheels are over rated too   ;D

I like how this guy thinks!!!  ;D

Andy
Title: Re: Frank's Rainbow 2000 (.45-.55 size) build
Post by: Ededge2002 on May 25, 2018, 06:32:33 PM
Wheels are for cars!
Title: Re: Frank's Rainbow 2000 (.45-.55 size) build
Post by: Frank v B on May 26, 2018, 10:51:02 PM
Thanks Ed. ;D

I don't say my hand-launched planes don't have wheels, they have poor man's retracts. ;)

Frank
Title: Re: Frank's Rainbow 2000 (.45-.55 size) build
Post by: Frank v B on May 27, 2018, 10:09:21 PM
Finished both wing halves.  Installed the servos, control horns and control rods.

I am trying to figure out whether the wing can stay in two halves.  There are two aluminum joiner rods but the instructions say the rods need to be epoxied in and the root ribs glued together.

Tried to look up on RC groups and other websites but no clues whether the wing can stay apart.

Frank
Title: Re: Frank's Rainbow 2000 (.45-.55 size) build
Post by: Frank v B on June 10, 2018, 09:20:15 PM
Back to work
- aileron servos installed.  See photo of the top and the bottom of the wing.
- Wing tubes glued in place.  The instructions state both wing halves should be glued together but a 72" wing with a wide chord is tough to store and transport.  Nowhere on RCCanada or other websites does it have posts on options.  Have done the ultimate compromise.  Glued the main spar tube into the port wing and the trailing edge tube into the port wing.  This way it is locked in place but the wing can still be taken apart.
- cut out the covering for the stab.  This required the careful measurement to make sure it is square to the fuselage.  A lot of measuring and adjusting.  The covering has to be cut so the glue holds wood to wood for strength.

The installation order is:
1) install the main wing in its proper mount with the proper screws
2) install the stab per the cut-outs so it is square when viewed from the top.  Then adjust it when viewed from the front so the stab is in line with the wing.
3) install the fin/rudder once the stab is set.  It is set at 90 degrees to the stab.

getting there.


Frank
Title: Re: Frank's Rainbow 2000 (.45-.55 size) build
Post by: Frank v B on June 10, 2018, 11:01:17 PM
1) assembled the wing for the first time.  The tubes slide in fine.
2) glued the stab in place with 5 minute epoxy.  Note: the hinges have not been glued in place yet
3) glued the fin in place.  The rudder hinges have not been glued in yet.  The bottom hinge goes into the fuse so it cannot be installed until the fin glue cures.

It's starting to look like an airplane... a large one at that!

Frank
Title: Re: Frank's Rainbow 2000 (.45-.55 size) build
Post by: Frank v B on June 11, 2018, 11:02:41 PM
There is a finish line.... in the distance!! :)

Tonight did the following:
- hinged both elevator halves
- hinged the rudder
- fished the pushrods through (2 for elevator, 1 for rudder)
- installed the tail wheel
- installed 3 control horns (2 elevator, 1 rudder)
- linked the elevator pushrods and connected them to the servo
- connected the rudder pushrod to the servo
- installed the receiver and bound it to one of my DX 6's.  The wigglers worked perfectly.

Tomorrow the cowl.  This may become a bit of a time stealer if the spinner back plate clearance with the front of the cowl is not correct.

Frank
Title: Re: Frank's Rainbow 2000 (.45-.55 size) build
Post by: Frank v B on June 17, 2018, 09:28:58 PM
A quick non-photographic* update:

installed the cowl- it was fiddly for two reasons:
i) I had to bring the motor out by using two washers under the firewall bolts
ii) there is right thrust in the motor but not in the cowl.  Had to find the exact angle where the spinner backplate would clear the cowl and the motor housing did not rub against the cowl.  Remember, the motor is about 75% lager than called for on the plans.
Secured the cowl with 4 socket head washer screws.

I will be delivering the plane to the store this week... to pick up the next project.

Frank

* this way Andy cannot use his Fill Flash comments. ;D
Title: Re: Frank's Rainbow 2000 (.45-.55 size) build
Post by: Andy Hoffer on June 17, 2018, 10:53:03 PM
Quote from: Frank v B on June 17, 2018, 09:28:58 PM
A quick non-photographic* update:

installed the cowl- it was fiddly for two reasons:
i) I had to bring the motor out by using two washers under the firewall bolts
ii) there is right thrust in the motor but not in the cowl.  Had to find the exact angle where the spinner backplate would clear the cowl and the motor housing did not rub against the cowl.  Remember, the motor is about 75% lager than called for on the plans.
Secured the cowl with 4 socket head washer screws.

I will be delivering the plane to the store this week... to pick up the next project.

Frank

* this way Andy cannot use his Fill Flash comments. ;D


Oh, you mean like for photo #1842 in http://temac.ca/smf/index.php/topic,6598.msg43570.html#msg43570?!!

8)

Andy
Title: Re: Frank's Rainbow 2000 (.45-.55 size) build
Post by: Frank v B on June 18, 2018, 10:04:27 PM
Andy, you spelled it wrong!

your statement "Oh, you mean...." should really be spelled "Oh, you're mean" ;D

Your Buddy,

Frank
Title: Re: Frank's Rainbow 2000 (.45-.55 size) build
Post by: Frank v B on June 22, 2018, 11:32:41 PM
Last few details done tonight.  Tomorrow (Saturday) before noon it is going back to John's Hobbies.  Roger will add the ESC and bind the RX to the customer's transmitter and voila!

The last details were:
- attaching the landing gear for the first time
- building an extension to the battery box.  There may be a CG problem because the motor is a .90 for an airplane designed to fly with a .55.  I extended the battery box backward until it is in the pilot's nether region.  This way the 8 cell pack (2 -4S packs) can be used to find the proper CG.  Cannot do it now because the ESC has not been installed yet.
- assembled and bagged all the extra bits, the instruction booklets (plane, RX), the extra (small) wheels, wheel pants, spare screws, etc.

Done.

Frank
Title: Re: Frank's Rainbow 2000 (.45-.55 size) build
Post by: Andy Hoffer on June 23, 2018, 09:23:35 AM
Way to go @Frank v B !  I am looking forward to your formal portrait of this completed masterpiece from a nice low (down on the ground) realistic angle, with precise focus from tip to tail, with fill flash, with balanced exposure, with perfect white balance and an uncluttered, defocused background!  8)

(I'll bet the soy beans are relieved to hear that this plane is going back to John's Hobbies!!)

Cheers!

Andy
Title: Re: Frank's Rainbow 2000 (.45-.55 size) build
Post by: Frank v B on June 23, 2018, 04:00:15 PM
Andy,

I am drawing a blank. 
Oh, that is not my state of mind, it is describing the photo.  There ain't one. ;)
No photo, no critique, no snide comments.  Problem solved. ;D

Frank
Title: Re: Frank's Rainbow 2000 (.45-.55 size) build
Post by: Frank v B on June 23, 2018, 06:20:54 PM
The plane was delivered to John's Hobbies at 10:30 am today, Saturday, June 23.  Picked up my next assignment.  The link is http://temac.ca/smf/index.php/topic,6655.0.html

Frank
Title: Re: Frank's Rainbow 2000 (.45-.55 size) build
Post by: Frank v B on July 14, 2018, 09:11:33 PM
Just got a phone call today from the owner.  He maidened the plane today and said it flew incredibly well.  He said it had lots of power.  I hope so.  The motor was twice the size recommended.

I mentioned to the owner that this kit was of phenomenal quality.  Everything fit, nothing had to be sanded.  The stabilizer and fin were perfectly square when slipped into their slots.  First time ever in my experience.  The covering was meticulously applied, the edges accurately trimmed.  In my book its gets a 9 out of 10.  Equal to or better than E-Flite/Horizon.

Frank