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Old Jul 21, 2013, 12:50 PM
That Freeking Laird Guy
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United States, CA, Riverside
Joined Feb 2002
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Build Log
Zephyr-mania Build Thread

Let's start a new Thread for the actual building of the Zephyrs. We got about 1/2 of the kits handed out yesterday at the Cave O Wonders. I think Rubio has 10 or so for the OC guys. I still have a few Fuses here at the house and Dan has the rest most of which will be shipped. Please contact Dan if you want your plane shipped.
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Old Jul 21, 2013, 01:13 PM
That Freeking Laird Guy
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First lets talk about the wing cores.

1) They are cut OVERSIZED and will need to be trimmed depending on your leading and trailing edges.

2) They are cut for 1/16 balsa sheeting. If you use thinner sheeting you will have a narrower chord when finished and will need to trim some additional material from the cores. If you are using 1/64 ply trim an extra .25" off the trailing edge (so your root chord will be 5.25"). I think you can get away with 1/32nd ply without trimming extra off the cores.
If you want to use the recommended 3/4" leading edge you trim 1/4" off the leading edge of the cores If you use a 1/2" leading edge don't trim anything. Now if you are using the recommended 2" trailing edge you trim the trailing edge of the cores so that the core dimensions are 5.5" at the root and 1.25" at the tip.

The finished Zephyr wing should be 8.25 at the root

The method I like is to sheet the cores as they are. Once sheeted, put them back in the beds and mark the beds with the dimensions you want. Then cut off the excess using a band saw. Then sand the leading and trailing edges to square them up. The you can install the LE and TE. Again Double check the dimensions
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Old Jul 21, 2013, 02:57 PM
Summer... is my time of year
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United States, CA, San Juan Capistrano
Joined May 2011
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Brian ,
Thanks for having the Build day at
"The Cave of Wonders".
For those of you who chose to do something else. You missed an informative and fun day.
Pismo and Greg , Matin, Tom ,Ed Brian and I had a great time building.
As always I learned so much!!
Just fun to see everyone and do what we love. Build PSS...!!

rubio
Who pushed send too soon.
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Old Jul 21, 2013, 03:13 PM
Just Toss It !!!
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United States, CA, San Diego
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Rubio's dining table looks like a dealership now!
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Old Jul 21, 2013, 03:14 PM
It's not going to build itself
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Aliso Viejo,CA
Joined Aug 2005
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Brian was using the powerplaner on the T/E too, that's Bada$$!

Tom
who once experienced the COW
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Old Jul 21, 2013, 04:16 PM
I want it to go fast...
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San Diego
Joined Sep 2006
797 Posts
Thank you for hosting Brian...as always just spending an hour is worth years of knowledge.

Fuse work by Dan was tremendous...way to get more people flying this sexy design.
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Old Jul 21, 2013, 04:34 PM
Summer... is my time of year
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United States, CA, San Juan Capistrano
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Quote:
Originally Posted by MATIN View Post
Rubio's dining table looks like a dealership now!
Right now it is....



Rubio
OC Zephyr Dealer
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Old Jul 22, 2013, 01:29 AM
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Nipomo, Ca.
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Thanks Brian

I had a great time at the cow and met some great people. Thank you Brian for doing this and helping us build our planes. It was so worth the 4 hour drive one way. I learned a lot in such a short amount of time. I'd love to hang out there for about a week or two and build planes with you.

This build thread is a great idea. I'm glad your doing this. Thanks!!

Here's a few pics from the BUILD DAY.
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Old Jul 22, 2013, 08:24 PM
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I am truely jealous of tflg's "Big tool" ! WAY bigger than mine...
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Old Jul 22, 2013, 09:58 PM
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It ain't bigger than mine
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Old Jul 22, 2013, 10:30 PM
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Quote:
Originally Posted by TFLG View Post
2) They are cut for 1/16 balsa sheeting. If you use thinner sheeting you will have a narrower chord when finished and will need to trim some additional material from the cores.
Hi Brian, Thanks for the info.

I had planned to sheet the wings with 1/32nd ply, but I don't want to lose the wing area. Does anyone know if there is there much strength or toughness lost by going with the 1/16 balsa?

Thanks,
Dan
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Old Jul 22, 2013, 10:37 PM
That Freeking Laird Guy
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United States, CA, Riverside
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Quote:
Originally Posted by IneptOne View Post
Hi Brian, Thanks for the info.

I had planned to sheet the wings with 1/32nd ply, but I don't want to lose the wing area. Does anyone know if there is there much strength or toughness lost by going with the 1/16 balsa?

Thanks,
Dan
There is a considerable difference in durability between the balsa and 1/32 ply. However you can always glass the bejeezus out of the balsa. Put a couple of layers of 4oz glass and then it's probably a wash.
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Old Jul 22, 2013, 10:41 PM
That Freeking Laird Guy
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United States, CA, Riverside
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Quote:
Originally Posted by bluffman View Post
It ain't bigger than mine
Oh, stop you two. everyone knows it's not the size of your tool but how you use it. BTW, I've been told I "REALLY" know how to use my tool!
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Old Jul 22, 2013, 10:46 PM
Just Toss It !!!
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United States, CA, San Diego
Joined May 2004
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For me the reduced stiffness of balsa sheeted wings was less important than the fact that they're more "dingable" than a ply sheeted or bagged wing.
I'll say worry about the AUW you're aiming for and let that decide the sheeting material for you.
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