Toronto Electric Model Aviation Club Forum

Toronto Electric Model Aviation Club (TEMAC) => Building / Construction => Topic started by: Frank v B on January 05, 2018, 09:39:42 pm

Title: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: Frank v B on January 05, 2018, 09:39:42 pm
A customer gave me a kit that he bought over 20 years ago when he visited Japan.  He said he would love to see it fly and would like to be there for the maiden flight.  Tough assignment... but since the customer is always right I have to build it.

Please note the beautiful custom spun aluminum cowl.

It appears to be about 35 inch span.  Trust me, it will be overpowered.

Marutaka apparently was bought up by Royal quite a ways back.

Will start it when the Chica is ready for covering.  Gotta keep making balsa dust!!

Frank




Title: Re: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: BJROB on January 06, 2018, 08:15:22 am
This Kit looks good ;D
Can't wait to see the process of building,
then to see it in the air, :o
Aluminum cowling sounds interesting for CG :-\ 
Title: Re: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: Frank v B on January 06, 2018, 02:54:03 pm
BJ,

re: "Aluminum cowling sounds interesting for CG :-\ "

The cowl is probably a dollhouse cooking pan with the bottom cut out. :D

Frank
Title: Re: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: Frank v B on January 07, 2018, 02:40:55 pm
Just had to confirm that the plane was 4 channel... with ailerons.  Pulled out the plans.  Yep!  Good.... but then Cadez will probably pressure me into adding flaps. 

May just add flaps for the fun of it.
Title: Re: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: Frank v B on January 07, 2018, 09:58:34 pm
Holy sh...  I thought this was going to be easy.  This plane will be real work.  It is built like a .60 size airplane with liteply formers, stringers and sheeted fuse.  No instructions.  Just two parts drawings.

I thought this customer was being nice to me giving me this kit.  He was probably trying to punish me.

Followed the first 7 steps of a build project per Bruce's PT 19 thread:
Photo 1 Clean the workbench off and find the project
Photo 2 Found the project
Photo 3 Make sure it is the right project
Photo 4 and 5 Make sure all the parts are there and identify the kit's inspection certificate so you know who to blame when you can't find a part
Photo 6 Get prepared to lay out plans on work bench surface and to protect them from messy over-glue. I use waxed paper.
Photo 7 Determine what part of the plane to build first - I'm going to start with the fuselage.  Review and consider plan instructions.


I may modify this kit significantly.  Thinner sheeting, reduce the amount of sheeting, adding stringers.  Adds a whole new dimension to Bruce's comment "Review and consider plan instructions. (Unlike Frank, I will likely follow them.)"

Stay tuned.  Check my pulse periodically. ;D  If you notice a change in me at Wednesday's meeting, sign me up for Anger Management courses. 8)

Frank
Title: Re: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: Frank v B on January 08, 2018, 08:58:21 pm
Re: Anger Management:

How would you feel if these were the only instructions you had??

Photo 1) The extent of the construction instructions. That's it.   That's all.     A more detailed construction summary would be "glue all the wood pieces together in the correct place, sand, cover, install the electronics, go fly.  Thank you for buying Marutaka" ;D

Photo 2) the fuse pieces.  All are liteply.  Two formers have already broken.  I re-inforced them with balsa.

ARRGGGHHH! ::)

Frank


Title: Re: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: Andy Hoffer on January 09, 2018, 07:34:29 am
Excellent!  Another photo session in the making! 8)

Andy
Title: Re: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: electroflyer on January 09, 2018, 11:02:09 am
  Frank,
  What a cool little kit, I love the spun cowl!
Always a drag when the little pieces break, but once joined together it will all be good...if not, I can lend you my brick..LOL ;D
Title: Re: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: Frank v B on January 09, 2018, 08:46:32 pm
Glenn,

Thanks... but I will probably need the rest of your driveway as well. ;D

Frank
Title: Re: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: Frank v B on January 09, 2018, 08:59:33 pm
...well... every journey starts with a single step.

Started with the bulkheads/firewall.  Required a fair amount of digging since the cut-outs for the stringers were semi-circular and the longerons were square.  The old square peg and round hole trick.

Photo 3- the fuse as it stands after the first attempt.  Life was made much easier when I cut the two balsa cross pieces to keep the firewall sides up against the formers.  These were just force-fit.  The stringers were rubber banded together at the back so the Formers can be inserted once this assembly dries.

Photo 4- close-up of the glued nose area.  The balsa spreaders are clearly visible.

Photo 5- close-up of Former 7 showing the rounded slots.  All of them need to be made square.

Gotta put the project aside so I can prep for tomorrow's Pilots Meeting.

Frank
Title: Re: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: Frank v B on January 11, 2018, 09:23:27 pm
Back to building after last night's Pilots Meeting

Photo 6 - had to put re-inforcements on all the formers after two broke.  Also, when inserting them between the two stringers, they would bend so I put 3/16 square pieces across them.

Photo 7- The formers were all glued in place and held with rubber bands while the glue dried.  No attempt was made to cut them to length.  Easier to do when the glue is dry.

Photo 8- Photo from the top.

Photo 9- more stringers in place, ends trimmed.

Photo 10- The two wing saddle pieces.  Marked Port and Starboard. 

Photo 11- Held under the tap to wet them.  Then slipped a wet paper towel in between them so more moisture soaks up the exterior side to make them bend.  They will bend away from the wettest side.  They get glued in once the main fuselage is dry.

Frank

Title: Re: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: Frank v B on January 12, 2018, 08:31:03 pm
Photo 12- side view of the middle fuselage sheeting.  Both port and starboard were done at the same time.  Only the bottom of the sheet was glued.  It is pinned to dry.  This way when I go to bend the wood, the bottom will stay in place.  I will let this dry overnight and then pull the top part of the sheeting in place. I do both sides at the same time so the fuse stays straight.

Photo 13- view from the top.  It shows that the top of the sheeting is not attached to anything.  Also showing is the outline of the top front hatch for battery and plug access (behind the firewall).  Also the motor mount box has the top and bottom closed for strength.  Also put a floor under the battery hatch so the battery stays in one place and the Velcro can be stuck to a flat surface.

Power: have decided to power it with an E-Flite 450 purchased at last Wednesday's Club Auction. This motor is longer than the second option which is a Supertigre .10 out runner.  The .10 is quite a bit shorter and easy to install.  Will make the final motor decision prior to the maiden flight once I have a chance to weigh the final model.  It may have the flight qualities of an aerodynamic brick. ;D

Yes, am planning on a 3 bladed prop for scale-like looks... also bought at the Club Swap Meet.

Frank
Title: Re: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: octagon on January 13, 2018, 11:40:53 am
Back to building after last night's Pilots Meeting

Photo 6 - had to put re-inforcements on all the formers after two broke.  Also, when inserting them between the two stringers, they would bend so I put 3/16 square pieces across them.

Photo 7- The formers were all glued in place and held with rubber bands while the glue dried.  No attempt was made to cut them to length.  Easier to do when the glue is dry.

Photo 8- Photo from the top.

Photo 9- more stringers in place, ends trimmed.

Photo 10- The two wing saddle pieces.  Marked Port and Starboard. 

Photo 11- Held under the tap to wet them.  Then slipped a wet paper towel in between them so more moisture soaks up the exterior side to make them bend.  They will bend away from the wettest side.  They get glued in once the main fuselage is dry.

Frank

Frank, If I had not known before I could tell you are a sailor. Port and Starboard wing sadles, LOL!
Title: Re: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: Frank v B on January 13, 2018, 08:31:41 pm
Rob,

re:"Port and Starboard wing sadles, LOL!"

Left and right is a direction.  Port and Starboard is an orientation... relative to the pointy end of a boat or an airplane.

Sorry to be picky and detailed.  Heck, Andy must be starting to rub off on me.  Oh no! ;D

Frank
Title: Re: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: Frank v B on January 13, 2018, 09:10:36 pm
Back to work,

Photo 14- side view of the fuse with the midsection, turtle deck and half of the top sheeting done.  The plane looks like a pin cushion!
The small structure under the plane is the cut-out section for the battery hatch on the top deck.  Once the top sheeting has dried in front of the cockpit, I will cover the hatch.

Photo 15- Top view of the pin cushion.  I could not bend the wood over the top stringer as per the plans because balsa does not bend that much in such a short distance.  I glued a piece of wood (approx 1/4"sq) onto the top stringer and butted the sheeting up to its two sides.  Once dry, I will plane/sand it does and round it off nicely.

Note: in the sheeting and stick work- no attempt was made to make ends line up.  All pieces were left long, even in the cockpit area.  Once everything is in place, it will be trimmed properly and symmetrically.

Tomorrow- the hatch and bottom sheeting.

Frank
Title: Re: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: Frank v B on January 13, 2018, 10:40:18 pm
Just did the hatch.

Photo 16- shows the hatch in place.  The wood was cut to size over the removable hatch.  The hatch frame was pinned in the correct orientation and height.  Waxed paper was slipped into the hatch ends (front and back) so glue would not get onto the fixed fuselage parts, just the hatch structure.  The wood was soaked with water to make it bendable and 5 minute epoxy applied, more pins to hold it in place.

Photo 17- Shows the top of the turtle deck detail.  The sheeting was supposed to go over the top and meet flat at a seam on top of the small stringer.  I glued the 1/4" square piece on top, cut the fuse sides so they meet the sides of the stringer and glued them in place.  The balsa sticks out on top of the sheeting but it will be made level when sanded and nicely rounded.  This is the part I referred to in photo 15.  You can also see in this photo why I did this.  The starboard side sheeting (left side in the photo) split and had to be glued.  That's when... and why... I added the 1/4" square piece on top.
Title: Re: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: octagon on January 13, 2018, 11:03:39 pm
Rob,

re:"Port and Starboard wing sadles, LOL!"

Left and right is a direction.  Port and Starboard is an orientation... relative to the pointy end of a boat or an airplane.

Sorry to be picky and detailed.  Heck, Andy must be starting to rub off on me.  Oh no! ;D

Frank
Now I am confused. aren't most planes pointy on both ends? :)
Title: Re: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: Frank v B on January 14, 2018, 09:48:33 am
Rob,

re: "Now I am confused. aren't most planes pointy on both ends? :)"

I know you sometimes fly backwards when you crash.  Do you also walk backwards?   You clearly have orientation issues.;)  Everything has a leading edge and a trailing edge.
Start walking backwards faster! ;D

Your buddy,

Frank
Title: Re: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: Frank v B on January 14, 2018, 10:12:21 am
Keep working Frank!!

Photo 18- Popped the battery hatch.  Only one corner was stuck and had to cut it free but everything else was protected by the waxed paper.

Photo 19- what the hatch looks like when it is closed.

Photo 20- Attached the bottom sheeting.  Like the top, I glued one edge first and let it dry, then later I will wet the balsa to make it curl, then trim and glue it.

Photo 21- Looking down the belly*.  I glued a wider stick onto the bottom (keel) so the sheeting can be cut up to it and then sanded.  It will stop the splitting problem.

Frank

* no Rob, not an official term but refers to "the belly of the beast". 8)
Title: Re: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: electroflyer on January 14, 2018, 11:37:05 am
     Wow, that is coming very nicely. Interesting construction with the skeleton being constructed first and then sheeted. As I will show on the Mosquito build, Half crutches are constructed, sheeted then joined together and hopefully straight.
  Looking good!
Title: Re: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: Frank v B on January 14, 2018, 11:46:26 am
Thanks Glenn.

The fuse in this kit can best be described as a Guillow's Rubber Band Kit which is then sheeted.  The fuse is only 23" long but takes as much time as a .60 size airplane.  The nicest part of a small plane is that balsa filler can cover up bigger mistakes.  Will still need half a truckload of the stuff. ;D

Frank
Title: Re: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: Michael on January 14, 2018, 02:40:17 pm
Nice work, Frank!

Title: Re: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: Frank v B on January 14, 2018, 03:13:27 pm
Thanks Michael,

I think I will shrink the size of the photographs as the project progresses... so you can't see all the gaps and mistakes.  50/50 rule applies*.  Will need the half truckload of filler.

Frank

* 50/50 rule- if you can't see it at 50 mph at 50', don't worry about it. ;)
Title: Re: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: Frank v B on January 16, 2018, 08:41:29 pm
Last touches on the fuse:

Photo 22- side view of fuse with aluminum cowl slipped in place.  First sanding of filler, tail piece added and shaped.

Photo 23- Top view of fuse.  Looks cool!

Now to set the fuse aside and build the wing.
Title: Re: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: BJROB on January 16, 2018, 08:49:03 pm
Wow Frank
that look so good
nice job...
Title: Re: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: Frank v B on January 16, 2018, 08:49:42 pm
Now Ve start da Ving.

Weird construction technique.  The main spar is one piece of slotted plywood from gull wing to gull wing.  Then glued 3x3 mil upper and lower wing spar on this plywood main spar.  Then slip in the ribs.  Impossible to pin this wing down in any way.

Photo 24- one half of the wing.  The colourful rubber bands were to hold the spars in place while the 5 minute epoxy dried.

Photo 25- the whole wing.  The ribs are just fitted in place (no glue) to determine how to build a straight wing without a building board. 


 A head scratcher. :P :-X :-\ :o :( >:(

Frank
Title: Re: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: Polecat on January 17, 2018, 10:21:57 pm
Hey Frank
Your build looks great, get it finished and bring it to Orangeville for the May/June race.
I saw another Corsair listed for sale on RC Canada, it had a 35" wing span and was kitted by Sterling. It might be a control line model, you could pick it and fly control line with Rick and Cory. The Brantford guys fly some control line at their club.
See you at Kitchener Swap Meet.

Ken
Title: Re: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: electroflyer on January 18, 2018, 04:21:29 pm
   Very interesting wing construction. I built a Topflite Corsair years ago and I believe it had tabs on ribs to allow it to be built on a board. It was still a bear to construct.
  Yours is looking great!
Title: Re: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: Frank v B on January 18, 2018, 09:05:41 pm
After a day sick in bed.... and silence for all Temac members, it is back to building a model airplane

Photo 26-  Right side (starboard) of the wing Slowly pulling everything together. None of the ribs have been glued on the main spar yet.  Started out with gluing the leading and trailing edge against the two outer ribs of each section then once the 5 minute epoxy dried, glued the rest of the ribs to the leading edge, let that dry, then the trailing edge let that dry and then do it over again on the second half.

Back to my old rule of thumb "build one half of the wings and then make exactly the same mistakes on the second half (chord, span, etc.) and it will fly fine."

Photo 27- the whole wing.  The second half is slowly catching up to the decisions/mistakes made on the first half.

It looks like very little was done but this was about a dozen separate mixes of 5 minute epoxy.
Title: Re: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: Frank v B on January 19, 2018, 08:23:58 pm
Today's topic:
How to straighten a crooked wing
How to make symmetrical mistakes.. but not those ones! ;D


Took out all the pins from the leading and trailing edges and guess what? a Crooked wing.... about 1/2" of wash-in.  Dangerous, unflyable.

Pinned the root of the wingtip section to the building board via a rubber band.  Used scrap trailing edge balsa to prop up the leading and trailing edge so root is at zero/zero.  Then propped up the trailing edge at the wing tip with a scrap piece of trailing edge balsa to give it about 1/4" wash-out (trailing edge higher than leading edge).  A total shift of about 3/4".  Cut and trimmed the top leading edge sheeting and glued it in place.  Held by the two rubber bands at the ends and pins in the middle.  When this dries, the wing should at least be straight.  Then I will install the bottom leading edge sheeting and pin it to the board again while it dries.

Whatever the result of this wing straightening, I will duplicate it on the other wing half.  At the covering stage I will be able to give it some more was-out by twisting the wing while it cools.

Sorry Bruce.  No "T" pins.  Note how I cut back on the pretty pink pins ;D


Title: Re: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: Andy Hoffer on January 19, 2018, 09:45:44 pm
Rob,

re:"Port and Starboard wing sadles, LOL!"

Left and right is a direction.  Port and Starboard is an orientation... relative to the pointy end of a boat or an airplane.

Sorry to be picky and detailed.  Heck, Andy must be starting to rub off on me.  Oh no! ;D

Frank

Bummer!!   8)

Andy
Title: Re: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: Andy Hoffer on January 19, 2018, 09:54:20 pm
Today's topic:
How to straighten a crooked wing
How to make symmetrical mistakes.. but not those ones! ;D


Took out all the pins from the leading and trailing edges and guess what? a Crooked wing.... about 1/2" of wash-in.  Dangerous, unflyable.

Pinned the root of the wingtip section to the building board via a rubber band.  Used scrap trailing edge balsa to prop up the leading and trailing edge so root is at zero/zero.  Then propped up the trailing edge at the wing tip with a scrap piece of trailing edge balsa to give it about 1/4" wash-out (trailing edge higher than leading edge).  A total shift of about 3/4".  Cut and trimmed the top leading edge sheeting and glued it in place.  Held by the two rubber bands at the ends and pins in the middle.  When this dries, the wing should at least be straight.  Then I will install the bottom leading edge sheeting and pin it to the board again while it dries.

Whatever the result of this wing straightening, I will duplicate it on the other wing half.  At the covering stage I will be able to give it some more was-out by twisting the wing while it cools.

Sorry Bruce. No "T" pins. Note how I cut back on the pretty pink pins ;D

Please see http://temac.ca/smf/index.php/topic,6455.msg41987.html#msg41987

If you insist on using "unmanly pins" you will get "unmanly curves" in your wings!  For heavens sake, heed the admonitions of our sagely CFI!!  8)

Andy
Title: Re: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: BJROB on January 20, 2018, 07:59:04 am
Sorry Bruce.  No "T" pins.  Note how I cut back on the pretty pink pins ;D

Frank ...its ok to use pins of colour as pink is just a colour ;)
Title: Re: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: Frank v B on January 21, 2018, 11:40:01 am
Back to work.......

Photo 28- shows the close-up of the port wing half.  The leading edge is closest to the camera.   The leading edge sheeting trick worked and the wing is now straight.  The bottom leading edge sheeting has not yet been done.  The photo shows the landing gear block in place (below the rectangular balsa doubler).  The original design was just the landing gear block sitting in between the two ribs with a plywood rib doubler on each rib.  Not enough, especially since I know who will be flying this thing.

Have added the balsa triangle re-inforcement at the leading edge to brace the landing gear.

Have added triangle braces at the trailing edge where it splits and the aileron starts.  Without braces, this would be a very weak area.

Photo 29 a close-up of the center section with all braces in place and drying.

Bruce, please note how large the photos open up when you click on them.   Just for you.  If you still have problems seeing them I will add a Braille setting. ;)
Title: Re: FRANK'S 1/2A F4U CORSAIR BUILD
Post by: Frank v B on January 21, 2018, 02:35:19 pm
Sheeting the center section.

It was very obvious that each wing bay had to be sheeted individually because of the compound curves.

The original plan was to put the top and bottom on at the same time and glue them from the trailing edge up to the high point in the rib (spar), let it dry, then draw it together at the front and glue it in place.  Problem was the clamps kept sliding off the leading edge.  Ended up glueing the entire piece onto the wing (top and bottom), then wrapping it with green tape to hold it in place.  There are 3 wraps of tape to hold it in place.  The first wrap would not stick because I had to soak the balsa to allow it to bend.  Tape does not like moisture.

Photo 30- view from the bottom of the wing.  You can see the landing gear blocks in place here.  Bruce: the photo is a little blurry.  It should normalize after two beers. :D

Photo 31- two sides done and allowed to dry.  The one clamp is to keep the sheeting flat on the rib.

Photo 32- My new favourite piece of woodworking equipment- Roger Mason's carbide stick.  It makes sanding so fast, accurate and easy.  It has a fine and course end... just like the man himself. ;)