BT Electric Corsair

[CUBANO8]

I am planing on building a Brian Taylor 82" Corsair.
http://www.bhplans.com/BTPlansPg1.html
This is what I have so far:

Plans: from Bob Holman
Laser cut parts & spinner: from Bob Holman
Cowling, wing crank, and canopy: Ordered from Bob Holman/Brian Taylor(on order)

Retracts: Century Jet #13334(on order)
http://www.centuryjet.com/webstore/moreinfo.cfm?Product_ID=220&CFID=378&CFTOKEN=22823881
Motor: AXI 5330/18
ESC: Jeti 90
Batteries: True RC two 5s2p 8000mah(on order)
http://home.comcast.net/~truerc/custompack.htm
Servos: Hitec 645

I will make this build a simple as possible to keep things light. I am going to try to cover the plane with film covering instead of fiberglassing, again to keep things simple and light. The covering that I am going to use is LiteFab, with balsarite, and then paint over it. My target weight is to keep it under 20 lbs.

http://www.nelsonhobby.com/covers.html

Most of the wood was ordered from National Balsa Co.
http://www.nationalbalsa.com/index.html

Sam

[CUBANO8]

Today I recieved my Lipo Packs from True RC, here are the dimensions and weights.

Height - 2 3/2"
Length - 5 1/2"
Width - 2"(one pack) 4"(two packs)

The two packs together weigh 3 lbs. 15.6oz , and one pack weighs 1lb 15.6oz. The weight is going to be quite helpful, from my exp with warbirds.

Again these packs are 5s3p 8000mah for one, I will put these two in series for a total of 10s (37volts).

These packs are rated at 10c discharge or 80amps max. I will not reach that, I plan to go max 75amps(60seconds) , and a continous 60amps which is what the AXI 5330/18 is rated for. Input power between 2220 - 2775 watts.

[hermperez]

Hey Sam, good thread.. I finally saw that nelson litefab that you will be using.. it is about the same as the polyester dress liner I use (remember the big orange kadet senior?), probably the same fabric but with adhesive and paint added. Polyester dress liner is 1.8oz per square yard.. about $3.50 per linear yard by 44" wide. Full scale airplanes use it as glider grade ceconite.

The litefab is much lighter than the other painted fabrics in the market, not a bad choice if you want to avoid painting.

[CUBANO8]

Thanks Herm, Here are the pictures of the front and rear braces. I need to get two air tanks from my LHS tomorrow, which will go in the wing. BTW I decided to go with the spruce spar.

[CUBANO8]

Here is the placement of ribs #2,3,4,5a over the plan, nothing is glued until I get 1/4" x 1/2" spar.

[CUBANO8]

I went to my LHS today, but they did not have the air tanks, so I will have to place an order for them. I did make the holes to accept the air tank. I made a 2 1/4" hole at the front section of rib#2,#3,and#4. The tank is 8 inch in length so the bottom will rest on rib#5.

[CUBANO8]

I also made holes to the ribs for the air tubing, and the servo wires. Then I place #2 center rib,3,4, and #5a center with the bottom 1/4" x 1/2" spar on the plans. I aligned them and glued them in place. After that I glued the top spar, shaped the rear top 1/4"x1/4" spar, and glued it in place.

[CUBANO8]

Here is two pictures of the front brace and joiners after the glue has dried.

[CUBANO8]

...and here's what it looks like with the rib assembly attached, not glued yet. I still have to glue in the webbing and start on the left side center wing section.

[CUBANO8]

I've started on the left center wing section, the same steps as the right side. I then clamped both sides to the front brace to see what it looks like.

[CUBANO8]

The outer portion of the wings consists of ribs 5B,6,7,8,9,10,11,12,13,14,15.

[CUBANO8]

My aileron servo will reside between ribs 8, and 9. My flap servo will reside between 5B and 6. I plan to make an access hatch to get to these servos, similar to the ones found on today's ARF's.

[CUBANO8]

I've made holes to both left and right wing ribs at 6,7, and 8, I will do 5B another day.

[CUBANO8]

Here's what it will look like, nothing glued yet.

[CUBANO8]

Here's rib 5B that I forgot to post.

[CUBANO8]

Before I began to glue the ribs to the bottom spar, I had to taper the outer end of the spar according to the plans.

[CUBANO8]

I then set the bottom spar on the plan and glued the ribs from 5B thru 14. I left out rib 15 until I got the top spar glued in.

[CUBANO8]

I then proceeded to glue the top spar in place.

[CUBANO8]

I cut the small tapered piece, and glued it to the top of the bottom spar, which allowed me to glue rib 15 at the end

[CUBANO8]

I then glued the rest of the 1/4" spars to the rear of the wing

[CUBANO8]

Got the bottom 1/4 x1/4" spar glued in place, Also worked on the middle wing webbing ,and the rear webbing. Glued in the 1/4x1/8" and the 1/4x1/4" rear bottom spar.

[CUBANO8]

Took the wing off of the plans, and finished gluing in the rest of the webs in place.

[CUBANO8]

Drew the bottom part of the wing where the tabs needs to be removed, and cut and shaped them.

[CUBANO8]

I then worked on the 1/8" LE support, I placed the 1/8" x 2" strip in front of the ribs, marked both the top and bottom sides, and made my cut. I then glued it in place of the LE.

[CUBANO8]

Got the TE wing aileron and flap 1/8" support cut, and glued in place.

[drksyd]

Great build thread, looks like you have some good progress too. I like how the wing ribs have the tabs so you can build it flat on the plans.

[CUBANO8]

Yes, it definatley helps getting the wing aligned. I wouldn't be too happy without them.

[CUBANO8]

I started with the ailerons, I placed the drawing over 1/16" balsa sheet traced the outline, I then cut it out. I am doing both sides at the same time.
Afte my cuts I drew in the aileron ribs location 9 thru 14. Then it was a matter of gluing them in place.

[CUBANO8]

I then started with the aileron LE. I got a block os soft balsa 1"x1"x12" for this process, and added a smaller block at the end. I cut it to fit and glued them in place, and shaped the LE. I will add support internally for the hinge area at a latter time.

[CUBANO8]

I got the hinge support blocks glued to the ailerons and the TE. I also glued the Hinges to the ailerons. The Hinge that I am using is Robart Super hinge 310.

[CUBANO8]

I started to redo the brace's and joiners, they all were warped. I tried to apply windex, and reshape them ,but I finally decided to get some 1/8 plywood, use the pieces i had as templates and cut news ones out.
I did the front, and rear center braces and joiners, and glued the two center sections to them.
I also received the Century jet retracts, they look very nice!

Sam

[CUBANO8]

Here are some pictures of the retracts over the plan where they will be located, and some dimensions of the retracts.

[Coastwatcher]

My head is spinning trying to asorb all this work.......whew ....I'm getting tired watching you work. So ? this is what is inside of our airplanes ...humm........ I thought my ARFs grew in a magic garden in China . :)

I'll keep following this and maybe in 100 yrs I'll know enought to start to do one of these.

In the meantime ........nice work SAM !!!

[CUBANO8]

Thanks Fred, I'm getting ready to start a new build thread on a Jap Warbird too in the scale section. :)

Sam

[CUBANO8]

Got a little bit more done on the center section. I glued in the rear brace and joiner assembly, also added the bottom 1/4" spar to the TE and glued in the center #1 rib and the top 1/4" support.

[Rob Schaffer]

Very Nice project. I'm looking to build a big corsair in the future as well, and I thank you for the links at the beginning of the thread.

I recently built the Top Flite 60 corsair, and powered it with an AXI 4130 on 6S, flies fantastic.

Keep up the good work!

[CUBANO8]

Thanks Rob, I saw your Corsair thread, really looks nice ;)

Here is the control horns I'm going to be using, they are from Great Planes, the large scale ones Part# GPMQ3902, they come two in a pack.

Here is the installation of the aileron horn, I did use a 3/32" plywood sandwiched between the horn and back plate for extra support.

[CUBANO8]

I first make my measurements, and cut form 1/16" plywood to make my servo mount plate. Then I start constructing my servo mount plate support on the wing by using 1/4"x1/4" basswood. Then I make my servo arm openings on the plywood, and I support my servo to the plywood with 1/2" hardwood glued in place.

[CUBANO8]

I continue using 1/4"x1/4" basswood to construct the support on the wing.

[CUBANO8]

I then secure the servo mount assembly to the wing with wood screws.

[drksyd]

Nice build Sam, looks like your making some good progress.

[CUBANO8]

Thanks drksyd, I received the accesories from Brian Taylor, including the wing crank, Cowling, and canopy.

[hermperez]

all right!, so now you will crank into high speed building mode?, maiden in 2 weeks? :)

That cowling is about the size of a 5 gallon bucket?

Thanks drksyd, I received the accesories from Brian Taylor, including the wing crank, Cowling, and canopy.

[CUBANO8]

all right!, so now you will crank into high speed building mode?, maiden in 2 weeks? :)

That cowling is about the size of a 5 gallon bucket?

The cowling is pretty big, I probably could've made one from a bucket :)


Here's an update on my build, I got the left wing started, Soon I will join the wings and start on the flaps and my favorite part, the landing gear.

[CUBANO8]

I finished the other wing, same process as the first. I also finished both ailerons. I then sanded, filled in the gaps, applied balsarite to the surface, and covered both ailerons with the litefab material.

[CUBANO8]

Also completed the servo installation for the left wing, same as the right.

[CUBANO8]

with both outer wings done, i started to build the front and rear braces that will support the center section to the outer wings. The front, and rear brace consisted of three pieces glued together to make one.

[CUBANO8]

once done I glue them to the center section.

[CUBANO8]

..and after this I started to glue the rear braces. This is where I'm at with the build. I will finish gluing in the braces and then I'll glue both outer wings to the center section.

[hermperez]

so how did you like covering with the fabric?, pretty easy is it not?

[CUBANO8]

so how did you like covering with the fabric?, pretty easy is it not?

The trick to this covering is to get the amount of heat correct, too much and it will bubble up, too little and and will peel off, around mid range will work.

Sam

[CUBANO8]

Finished gluing in the rear braces to the center section, and after this I glued in the outer left wing to the center section.

[Coastwatcher]

Sam.......... your going to have to hurry if your going to make Hermperez's deadline of two weeks :)


Looks great !!!!

Steady as she Goes !!!!

Fred

[CUBANO8]

Sam.......... your going to have to hurry if your going to make Hermperez's deadline of two weeks :)


Looks great !!!!

Steady as she Goes !!!!

Fred

:D Thanks Fred, If it wasn't for the 3 other builds it would've been flying by now :D

I did finish gluing in the right side to the center section, and now I have a complete wing. Space is becoming an issue.