Frank's HK foam DG 1000 power glider repair

[Frank v B]

One of Ken Ross' planes that fell into my car was a 2 meter foam glider with a retractable power unit.  It had a 370-ish brushless motor with a 7x6 prop.

Problem- the retract mechanism (plastic) was completely broken with pieces missing.
Repair approach- lose the retract power unit, install a regular folding prop in the nose.  Fixed the broken wing tip with 5 minute epoxy and a pin. (photo 67)

There was obviously a smoked ESC because of the blackened foam at the wing joint and the plywood keel (see photo 66).

Ripped out the standard size retract servo with the wheel attached and removed the whole power retract mechanism.

Next Step- figure out how to install a power 450... from last month's mini auction.

https://www.youtube.com/watch?v=XgVQE5U8VLg

Frank

[Frank v B]

Installed the motor- picked an E-Max 2822 (approx 150 watts).... mostly because it had a folding prop on it that fit.  Found two liteply circles and mounted the motor.

Cut the nose off the fuse with a razor saw.  Cut in a fair amount of down thrust.  Cut a ring in the foam to act as a slot for the plywood motor mount.

Mounted the motor on the plywood rings, cut in a slot for the motor wires.  Installed the motor into the fuse and taped it in place with masking tape.  Dropped in 5 minute epoxy to hold it in place.  Set it aside to allow the epoxy to cure.  Then  tomorrow will back-fill the joints with epoxy and glass cloth.

Frank

[Frank v B]

Adding the magnetic hold-down for the canopy.

Added two magnets.  Am tired of having them sink into the hole and not sit flat.

Quick and dirty way: drill hole wider and deeper than the size of the magnet.  Add 5 minute epoxy, cover with a piece of wax paper and add a steel ruler.  It will automatically pull the magnet flat and to the surface.  No sinking feeling.

Frank

[Frank v B]

Flew it today.  Piker was kind enough to heave it skyward.  A little underpowered but it flew well.  Just did the readings:

OOPS! Only 85 watts (8 amps)  on new batteries.  This motor will take 14 amps continuous.  Will increase the prop size from the current 8" diameter.  An extra 25% power would be perfect.

Frank

[Frank v B]

Just changed the prop from an 8"x4" folder to a 10" x 7" folder.

The readings are now 130 watts versus the 85 watts with which I flew today.

Mission accomplished.  Most flying will be done at 100 watts based on today's flying.  At least there is now some reserve power.


Frank

[Frank v B]

Flew it today with the new prop (10 x 7 versus the old 8 x 4)  and it was a much different airplane.  The launch was at half throttle and it would gain altitude quickly at full power.  Nice combo now.  No need to fiddle more.


Frank