OLY2 Build Thread

[GLIDERGIDER]

Hey guys,
Last night I cut first balsa on the 99 inch OLY2 sailplane. This is my largest plane I've built. Prior to this one, I built a 72 inch sailplane.

Larry O and Todd are the first, and now I'm the third to build this OLY2.

This build is slightly modified from the kit suggested plan.

Instead of a 2 piece wing, this one is a three piece.

Instead of steel wing joiner rods, this will use carbon joiner rods.

Instead of rubber band wing mounts, this one will have nylon bolt fuselage mounts.

Instead of a flat bottomed airfoil, this one will have a Philips entry on the leading edge. Photos below show the slight rounding of the leading edge.

One more mod to the airfoil is the 'D' sheeted leading edge.

Todd, what did I miss regarding the mods. (Todd and I are doing identical mods).

Dave

[atjurhs]

Dave, I think you listed almost all the mods.

I would just clarify that by a three piece wing you mean a total of four dihedral breaks across the wingspan vice the three stock dihedral breaks. And that in the center panel we are placing a single very large spoiler.

Also, we are changing out the wing tips for a much lighter solution.

And that our design modifications are being guided by the AVA & Bubba Dancer

[atjurhs]

I've been asked to post a few pics of my build.

Dave, can you please put these to a Shakespearean ballard :)

[GLIDERGIDER]

Thats B.E.A.U-tiful. Thanks for the inspiration.

Todd, you do good work. I can definately feel an epic is in the works with these parts. I'm starting to look forward to the maiden flights, of both you and Larry O. Are we going to invite the ARCR gang to the maiden party?

<you see how its starting to sound Shakespearian already? The Maiden Party.?..>

I will be posting some pictures of my build tonight, after I get home from the Grissom/Sparkman basketball games.

Dave

[GLIDERGIDER]

The main spar is assembled according to instructions, but not really. I haven't even looked at the instructions.

No need, because I have Todd's good pictures, and Larry Owens' most excellent build thread in the Thermal Forum. So, I'm golden.

There's really nothing better then building with balsa. <OK, yeah sloping foamies is better.> But a guy has to prepare for the the duldrums of summer ya know.

So, these past few days, I've

1) cut the relief for the ailerons,
2) Trimmed the spar caps with .007 carbon,
3) Epoxied the center 3 bays,
4) wrapped that area with kevlar thread.

Hey its a start.
Dave

[nuevo]

Looks super Dave. You're an inspiration for me to get mine going too.

[Miderror]

Any progress guys???

[atjurhs]

I've been wrapping my wing spar with kevlar thread. Two more bays and that will be done. After that, I'll either D sheet the wing, or start on the fuse.

So yes, there is definetly progress being made on mine. I hope the others brush off the cob webs on theirs....

[GLIDERGIDER]

Any progress guys???
How can there be any progress with so many distractions. Sloping was the first, then we had the DBPS combat, and now we have the FFF 4 channel ships. That's just too much fun. What a blast.
Dave

{note to self: finish the OLY by June 17th}

[GLIDERGIDER]

Windy all day today, and it just seemed like a great thing to do. So I dusted off my OLY2 build and started assembling the outer wing panels. I also worked on the mid panel too. So, I'm making progress.

[GLIDERGIDER]

Argh,
This morning, I took a look a the wing and was surprised to find a disaster. Last night I left the main wing joiner (drying with 20 minute expoxy) loose. I thought it had set up sufficently. This morning I find that the joint continued to settle plasticly overnight. It is a disaster. A big set back. I'll have to dig it out with a dremel.

[Johnnie Paul]

Argh,
This morning, I took a look a the wing and was surprised to find a disaster. Last night I left the main wing joiner (drying with 20 minute expoxy) loose. I thought it had set up sufficently. This morning I find that the joint continued to settle plasticly overnight. It is a disaster. A big set back. I'll have to dig it out with a dremel.


Ouch Dave, That is some tough luck, I hope you can slavage that joint...

Johnnie

[atjurhs]

Dave, sorry to hear that the OLY2 gods cursed you for letting her set and collect dust.

I finished wrapping my spar with kevlar thread last night shortly before midnight (the OLY2 gods would have cursed me had I not finished before midnight). I've probably got 20-25 hours in on wrapping with kevlar thread -arrrrg!

Now it's time to D-sheet her.

Next comes the fuse. I'm wondering about building her a full-flying elevator. Does anyone know of folks doing this with a OLY2?

[Jim_Marconnet]

..... I've probably got 20-25 hours in on wrapping with kevlar thread -arrrrg!

...
Just a question from the ignorant. What does wrapping these spars with kevlar and epoxy (if I understood it right?) do other than adding weight?

[GLIDERGIDER]

Just a question from the ignorant. What does wrapping these spars with kevlar and epoxy (if I understood it right?) do other than adding weight?
Think of the kevlar as a cast. Or a brace for an ankle. If you knew you were going to stress your ankle in a sporting activity, you might wear an ankle brace as a precaution. Wrapping the spar is much the same. The spar can shatter (fail) in an explosive manner. If you wrap it with thread, the thread will hold all the elements together and give the joint a much larger capability.

The epoxy that is giving me fits is part of a two piece wing joint. The join consists of a steel rod, and the rod fits into a brass recepticle. I was mounting the brass receptical in a bed of epoxy. The rod and recepticle allows the wing to be disassembled for transportion, yet when assembled, it is very strong.

[Miderror]

Good thing are rolling again.
Sorry I'm not in on a build of one too.
Limiting my irons in the fire.

Don

[GLIDERGIDER]

The wing is starting to look like something now. Its bones are full span now reaching 98 inches wide. The next operation is to glue the tips to the outerpanels. Then finish the ribs, add leading edges, trailing edges, and jeeze, I've still got a bunch of work to do.

[GLIDERGIDER]

Here I am working tirelessly on my OLY2. The wing is really taking shape now. The middle section is structurally complete. Even so, there are a lot of little items to do. The D sheeting on the middle is complete and the outer panels will get a some too. Then lots of "light weight" spackle to get a smooth airfoil. And yes the airfoil is kind of important on a thermal glider. I only have 17 days left before the fun-fly, and by golly I'm going to make it.

I really enjoyed watching Todd fly his Oly at last weeks contest. He caught a couple of great thermals and he was all grins. Combine a good thermal with a contest that demands a thermal, and there is some real pleasure in flying.

[Johnnie Paul]

It is looking good dave...remember to allow 15 hours for covering...I believe that was how long it took Todd to get that beautiful cover job on his. :)

My son and I plan to be there to watch the fun fly on the 17th.

Johnnie

[GLIDERGIDER]

I started forming up the fuse last night, and it goes together quickly. The instructions leave a lot to be desired, so I fudged my way though it using the plans. Oh, and the plans need the author's attention too.

Heres a picture showing the extent of my progress. Next I'll work on the tail feathers.

The wing is not the same wing as your father built when the original OLY2 was designed. Todd and I dreamed up this modification, and I really enjoyed building it. A three piece wing. At the outboard joints, this wing is just begging to become a pitcheron airplane.

The outboard panels have the original OLY airfoil. All the inboard panels are modified with a Phillips entry and D sheeting. Its going to be interesting to fly I'm sure.

[nuevo]

The instructions leave a lot to be desired, so I fudged my way though it using the plans. Oh, and the plans need the author's attention too.
no kidding !! Even the laser cut pieces don't fit right, and some don't match the plans.

Heres a picture showing the extent of my progress. Next I'll work on the tail feathers.
I just built my tail feathers. Take a close look at the plans. The elevator hingeline is not straight on my plans. I built to a ruler, instead of to the plans. There was slightly more than a 1/8" bow in the hingeline on my plans.

this wing is just begging to become a pitcheron airplane.
Polyhedral-pitcheron? I want to be there when you try it. Should prove to be entertaining. ... err I mean "interesting" :D

[dee-grose]

Hey Dave, is it just an illusion in the picture, or do the LE's not line up at the outboard poly breaks?

[GLIDERGIDER]

Hey Dave, is it just an illusion in the picture, or do the LE's not line up at the outboard poly breaks?

Yup, I'm adding a leading edge fence at that point to control the spanwise flow of air. The outboard airfoil is flat bottomed giving me a slight washout.

Plus, I like the looks. Its weird I know, but I like it.

[GLIDERGIDER]

Polyhedral-pitcheron? I want to be there when you try it. Should prove to be entertaining. ... err I mean "interesting" :D
You got it right the first time...Entertaining!!

No worries, I'm not going down that road.

[GLIDERGIDER]

I just built my tail feathers. Take a close look at the plans. The elevator hingeline is not straight on my plans. I built to a ruler, instead of to the plans. There was slightly more than a 1/8" bow in the hingeline on my plans.


Arrrg, mine too. Putting the laser cut parts on it was frustrating until I remembered your comment. I didn't see the warpage at first look.

[nuevo]

My stab joint curing... I plan to put a small patch of 2 oz fiberglass cloth over each end of the rod and extend about 1/2" top & bottom over the stab. This will greatly increase the surface area for that bond. On an old woody plane I used to have, a stab joint just like this one would fail after a hard landing or two.

[Thedraphter]

Jon,
That Elevator isn't going anywhere with all that weight on it. :)

For clarification: the glass cloth...are you adding it to the Horizontal Stab, or the Elevator? technically the elevator is part of the stab, but somehow, I'm not getting it...

DaveO

[nuevo]

I'm adding the fiberglass to the elevator (shown in the picture above). It will wrap around the dowel and back about 1/2" over the balsa. Here's a cross section diagram showing the dowell and the elevator balsa. The blue is where the fiberglass cloth will go. It's approx a 1.5" x .5" rectangle of glass with epoxy used sparingly. ok?

BTW, I have most of the sub-assemblies done, and still a lot of building to go. Getting down to the wire ! :o

[GLIDERGIDER]

I'm adding the fiberglass to the elevator (shown in the picture above). It will wrap around the dowel and back about 1/2" over the balsa. Here's a cross section diagram showing the dowell and the elevator balsa. The blue is where the fiberglass cloth will go. It's approx a 1.5" x .5" rectangle of glass with epoxy used sparingly. ok?

BTW, I have most of the sub-assemblies done, and still a lot of building to go. Getting down to the wire ! :o

Jon,
I didn't do the fiberglass thing for the elevator. Neither did I add the Flying Tail that I really wanted. Alot of it is cruch time and getting it done. But also, I'm starting to worry about the extra weight. Then I read that adding tail weight is a 3-1 disadvantage on weight because of the balancing effect of the short nose moment arm.

So, I'm considering strongly to mount the wing on the fuse last. Putting the wing CG directly above the finished fuse CG. I will of course be trading a shorter tail moment and I will loose turning authority. What do you think about that mod? Preliminary rough CG measurements put the wing as shown in the picture. Proportionally, it doesn't look to bad to me.
Dave

[Johnnie Paul]

A lot of hard work has paid off for Todd and Dave, as they have had serious fun at the Fun Fly at Sharon Johnston park today.

Altough very breezy, the seasoned pilots put on a good show with spot landings and duration flights.

New Daddy and avid flier Andy, I believe, had the most flights, as he used the bungy over and over and over again for some beautiful soaring.

Todd and Dave seemed to work in tandem to accomplish the tasks needed to fullfil many of the certs and duration flights needed for the different competitions they competed in.

I have posted a few pics that I have taken, it was a cool event. My family and I enjoyed it immensely.

Johnnie

[GLIDERGIDER]

Johnnie
Thanks for the pictures, thanks for coming. I hope you get a glider so we can add you into the competitions.

My favorite flight of the day was Todd getting a 7 minute max round. I was Todd's timer, and am responsible to get Todd from the winch to the landing circle safely, keep his time, and yell at people in his way.

Today the wind was blowing pretty hard, so finding thermals looked impossible. Early in the morning it was just up and down. The 7 minute flight looked out of reach because of the wind. Then Todd caught a bubble and worked it up, ranging to the end of the field. The time was racking up, and at 5 minutes we confirmed that at 6 minutes he would come down for the landing to get his 25 point bonus for hitting the landing. Well at 6 min, he was still pretty high. I mean really high. (to the reader, one more rule, if you go over 7 minutes, zero score). So I was starting to get anxious, "Todd DIVE IT DOWN" So he did, and I got absorbed in his progress enjoying the action. Then Todd yells, "call the time". I look down, crap, I'm not doing my job. "Todd says, give me time every 5 seconds". So I get back in gear and start calling his time. He makes his pass, upwind, turns and starts down wind to base. 15, 14, turn base 13, 12, bump, spoilers 11, 10, 9, (I couldn't stand it any longer) GET DOWN GET DOWN NOW, 6, 5, 4, I stopped counting, GET DOWN NOW"...... And he did. Perfect score, plus a 25 point landing bonus.

We we all know how Todd gets excited and it's kind of fun watching him. He didn't disappointment me here either. That's why I like Todd, I get to yell at him. :) And he's all smiles.

Todd also got his Level I LSF tasks completed today.

[atjurhs]

It was indeed a fun day.

Many thanks go out to Jon for putting this really fun event together.

Dave and I make a good team. He has taught me alot! I owe him bunches, or was that lunches.

I think the funniest part was when I looked down at Dave's score card and saw my flight recorded on his card, not mine! My own wingman was stealing my score :rolleyes:

And the 5 flights for 25minutes contest winner was Dave (after I took my flight off of his card). And Dave made all his landings too. That was very tough in the wind, but I tell you, this guy can fly a pizza box if it has servos!

Rob G. got the longest flight of the day with a 13min flight. Lots of folks tried to get in that same boomer, but Rob kept it all to himself. Nice flight!

It was really great seeing all the old wood birds out there and in the air.

What fun!

[Johnnie Paul]

I thought I would give Dave and Todd's Oly II build thread a bump for my first question towards my own build...

I have been told that the Oly II plans and build instructions are for reference only, as they may not match very closely; case in point: I noticed that the laser cut elevator control surfaces do not match the plans (see photos 1 & 2).

How did you guys fix this?

My current idea is to build with the elevator controls first since they are laser cut, and match nicely spanning 24" across. And then match the remainder of the parts to these parts. Next I would work directly from the centerline to keep symetry, as the elevator on the plan is not symetrical. There is 1/4" difference on the right, and 3/8" difference on the left.

If there is this much room for fudging on the elrvator, should I expect more on the main wing?

Johnnie

[GLIDERGIDER]

Johnnie,
Hey, its great that you are getting started on your OLY2. Outstanding. Looks like you have run into the same problem that I faced. Ignore the plans, except for the piece count. Don't force the wood to the plans. Your intent to work about the centerline is a good one. Get all the pieces and start stacking them from top to bottom, then east to west. The plans tell you how they will go, but the CNC cut parts should fit together.

The shorter 24 inch span is no problem. Just assemble the laser cut pieces. The two center pieces in the right photo should be spaced to allow the vertical stab to fit tightly between.

Keep us posted on your progress.
Dave

[GLIDERGIDER]

I just looked back though this thread. Good memories.

[Johnnie Paul]

Thanks Dave...piece count, just remember peice count...

In most of the Oly II build threads I noticed that the solid rudder part gets left out left out in lieu of an all stick built rudder. Is this just a weight savings thing?

Johnnie

[chuckand]

Thanks Dave...piece count, just remember peice count...

In most of the Oly II build threads I noticed that the solid rudder part gets left out left out in lieu of an all stick built rudder. Is this just a weight savings thing?

Johnnie

I guess this thread answers my question.... you got it and have started building :D.

Chuck

[Johnnie Paul]

I guess this thread answers my question.... you got it and have started building :D.

Chuck

I couldn't stand it any longer, so I started work on some smaller assemblies that do not get any laminates (composites)...although I will use Jon Stones idea of a little glass at the elevator control surfaces.

I gotta head into work today and hopefully pick up my Majestic kit :D

The Oly II kit came with some Sig-Bond Aliphatic resin, but I believe I will need to go to Lowes and pick up some Titebond. The kit also came with some small T-pins, but I may need to get a few more just in case.

yep, you can say that the winter build season has started for me.

Johnnie

[GLIDERGIDER]

Johnnie,
The tail mod is to improve the aerodynamics of the tail. To reduce the drag. Long ago, the servos used need a little help with turning, so they used the overhanging pivot surface (balanced rudder) to ease the stress on the servos. This design is not the most aerodynamic though. I guess theres also a weight reduction with the mod. Heres a pic after getting rid of the balanced overhang.

http://www.rcgroups.com/forums/attachment.php?attachmentid=861933

Dave

[Johnnie Paul]

I did not look far enough ahead in my build to see this coming, :rolleyes: I just found a nice little problem...the third former is no wheres near where it needs to be.

Is this also par for the course?

Luckily I have not glued F3 in place just yet :mad:

Johnnie

[RMoore]

Johnnie,

I didn't have this problem with my OLY II which was purchased about a year ago. F3 needs to be just exactly aft of the wing trailing edge. The forward edge of the top fuse sheeting will rest on top of F3 and will butt up against the trailing edge. I suggest you do whatever is needed to make that happen. Make sense? If not I can make some pix of mine for you.

You're right though, the kit needs a good bit of consistency cleanup!

Randy

[fly1milehi]

Johnnie,
Its hard to tell what the issue is from your photos. Sort of looks to me like if you line up the bottom sheet with the plans those formers would line up just about right to the plans and to the laser cutting. Isnt F3 supposed to go further forward than you have it placed in your photo? Looks like the plans might be a bit confusing since it looks like there are two doubler lines to follow. One is a solid line and the other is a dashed line. I really cant tell from the photos and I dont have the plans or kit. Im just trying to help from your photos.
The short laser cut on the elevator halves however does looks like a bad mismatch between the parts and the plans
Greg

[nuevo]

I had similar problems with the Skybench plans. I think he's run them off on a copier, and the exact scale is blown out of the water. For example, the length of my fuse was a full 2" less than shown on the plans. :eek:

In your case, the problem could be caused by the floor piece being too long. Thus forcing the slot too far aft. I took a look at my Oly fuse. F3 belongs where it is shown on your fuse. Right behind the opening over the wing. If you have not glued F3 in place, cut off the bottom tab with a saw, and glue it to the side walls where the slots are shown.

[Ray Hayes]

I did not look far enough ahead in my build to see this coming, :rolleyes: I just found a nice little problem...the third former is no wheres near where it needs to be.

Is this also par for the course?

Luckily I have not glued F3 in place just yet :mad:

Johnnie


We had a laser cutting hitch take place that moved the slot in the fuse bottom reward. If you hold up building the fuse, you will be receiving a replacement piece. Note, the former is located correctly....... it is the location of the slot in the fuse bottom that is wrong.

No, this is not par for the coarse.

Ray

Sky Bench

[Johnnie Paul]

We had a laser cutting hitch take place that moved the slot in the fuse bottom reward. If you hold up building the fuse, you will be receiving a replacement piece. Note, the former is located correctly....... it is the location of the slot in the fuse bottom that is wrong.

No, this is not par for the coarse.

Ray

Sky Bench

Ray,

Thanks for taking the time to explain what has happened, and thank you for offering to make it right.

I actually have a fix for the dilema, that would not require you to send me any parts, very simple fix is all.

Johnnie

[Ray Hayes]

Ray,

Thanks for taking the time to explain what has happened, and thank you for offering to make it right.

I actually have a fix for the dilema, that would not require you to send me any parts, very simple fix is all.

Johnnie


Your welcome, my goal is to keep the woodys alive and well. The club is doing a marvelous job of promoting the fun of building and flying woodys.

A one of a kind event is my very favorite way to fly in a contest. Up here, I'm hoping to get it started with a Gulf Coaster as seen on this first page of my Wood Crafters 07 with Don Harris holding his GC.

http://www.skybench.com/woodcraft/index.html

There are several area guys building them, we will see if they get them in the air. The GC uses a Clarky Y airfoil, so it is a good choice for windy days. Don has been flying his for several years.

Also, for a one of a kind event, IMHO, this one was the best.

http://www.skybench.com/sunbird/index.html



Take care and have a good new year


Ray
Sky Bench
Home of Wood Crafters

[GLIDERGIDER]

Johnnie,
How's progress? Have the drops of glue stopped falling? We're looking forward to more pictures.
Dave

[Johnnie Paul]

Actually, since there are a few build logs out there for the Oly II, I have been blogging... :)

It is kind of a cool feature the RCG lets us use, just click on my screen name...

Johnnie