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Old Sep 27, 2009, 03:37 PM
1400 watt RW Zephyr
matwelli's Avatar
Taranaki New Zealand
Joined Sep 2003
1,336 Posts
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Mats 54" Zephyr RiteWing Build

No, not a MKIII by FORD (New Zealand Joke - not sure if the MKIII was anywhere else in the world), the 54" Zephyr by Chris Klique at www.ritewingrc.com

Just had to have one, big and floaty, able to carry alot of weight (think FPV, Aerial Photography) and alot of Batteries for long, high flights.

Photos show how big it is in comparison to my Lightning 36 and a pair of 3S 2500 mah batts. The Batts wont be arranged like that, will be a standard Batt Bay in the nose.

You can see from photos how much Gorilla Glue to expect to push thru the wing, when the spar slots are properly filled
The gorilla glue is mixed with water so it foams and goes off in 1-2 hours

Plans are in the air (no pun intended) with this one. Single motor/dual motor, havent decided, got to get the 36" Lightning done first to race Jacko up in Auckland this comming Thursday !

No photos of every stage of the build, theres enuff of those, so just the highlights
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Old Sep 29, 2009, 02:54 AM
Fly me to the moon...
Atom1025's Avatar
Sacramento
Joined Jun 2005
4,140 Posts
Twin Microdans Ohhh now your thinking bout it.......
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Old Oct 07, 2009, 05:01 PM
1400 watt RW Zephyr
matwelli's Avatar
Taranaki New Zealand
Joined Sep 2003
1,336 Posts
Quote:
Originally Posted by Atom1025
Twin Microdans Ohhh now your thinking bout it.......
Briefly, but common sense prevailed

Ok, progress

Bays cut, I can fit almost ANY battery in here

Servos Cut

Golden rod channels cut - I use the Wing spar soldering iron, and a straight edge, held 19 mm of the TE so the golden rod run is strait and tapers out of the wing nicely.

Motor Plate Cut in, went from the bottom of the wing, as I want it LOW to accomodate the L bracket taht teh Waypoint outrunner is bolting to.
As you can see in the pics, its resting rite on the Two main Spars (you can also see how the PU has filled every void in the EPP in that area)

Initially this was going to be a lite floater, for FPV/Ap whatever , but two things have changed - 1 something bigger is coming that will do that role, and 2, Trappys OSD video changed my View on the Zephyr, now building it like a sport wing.

Comments on the Build so far.

This is my 4th Wing, 3rd done the Rite way. This would have to be the easiest so far as far as placing gear, no longer measuring mm to squeeze batts and servos between the surfaces of the wing. the layout is nice and easy, and I still have about 15mm beneath the batts in the centre.

Initially I thought it was a big wing, but now it feels RITE.

Second thing - this is a hard wing to photo, had to put it on the kids trampoline and stand on a chair, and tilt the camera to get it all in !
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Last edited by matwelli; Oct 07, 2009 at 05:08 PM.
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Old Oct 08, 2009, 03:14 PM
Fly me to the moon...
Atom1025's Avatar
Sacramento
Joined Jun 2005
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Your works to clean Matt

So whats the motor gonna do? KV?
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Old Oct 09, 2009, 05:30 AM
1400 watt RW Zephyr
matwelli's Avatar
Taranaki New Zealand
Joined Sep 2003
1,336 Posts
Heh, you always say that Adam , kv is 1136 or similar, should do 90 mph on 4S and 600 watts
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Old Oct 10, 2009, 10:57 AM
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subscribed. nice work
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Old Oct 10, 2009, 01:15 PM
Fly me to the moon...
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Sacramento
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Hey Matt, I love the idea of the rounded Prop slot but I found it troublesome to cover and decided I would prolly not do it again. I think if I were to do it again I would glass the inside face of the prop cut out first and then overlap on that. Guess thats obvious but easily overlooked when you got a routine......

I made a bunch of relief cuts my self and that resulted in flat spots between cut, if you can visualize that?

I love it for bare foam though, no stress risers.
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Old Oct 10, 2009, 03:09 PM
1400 watt RW Zephyr
matwelli's Avatar
Taranaki New Zealand
Joined Sep 2003
1,336 Posts
Argh ! - doh !, thats what I have done, finished glassing top and bottom, and now about to try and sort prop slot, and I read your post ! heh oh well better late than never.

Definately curves on a bare EPP, that foam tears easily around there when you hit the deck and the weight of the wings trys to rip them off (momentum)

That area is going to look like poo, as it also has a recess for the motor shaft.

Going to load it up with a bit of extra 90, the weave gets realy pliable and see what I can do

Update 1 1/3 can 3m90 does a zephyr, did 4 thickneses of weave on the bottom front around battery area, did double thickness on spar line forward on the top.

Quote:
Originally Posted by Atom1025
Hey Matt, I love the idea of the rounded Prop slot but I found it troublesome to cover and decided I would prolly not do it again. I think if I were to do it again I would glass the inside face of the prop cut out first and then overlap on that. Guess thats obvious but easily overlooked when you got a routine......

I made a bunch of relief cuts my self and that resulted in flat spots between cut, if you can visualize that?

I love it for bare foam though, no stress risers.
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Old Oct 12, 2009, 12:33 PM
1400 watt RW Zephyr
matwelli's Avatar
Taranaki New Zealand
Joined Sep 2003
1,336 Posts
Jacko did a google sketch up and ran the numbers.

AUW is looking to be 1.8 kg (63 oz)


Following is re-posted from Jacko

"662 Sqaure inches taking into account the motor cut out and the elevons

So if ya take the AUW too be 1.8kg... and then convert all the numbers around ya end up with -

13.8 Oz/sq.ft

Rough guide to suggested wingloadings -

10 oz/sq.ft Glider
15 oz/sq.ft Trainers
20 oz/sq.ft Sport Plane
25 oz/sq.ft Fighters"

The above numbers are with 500 grams of batt on board.

I can add 100 grams of nose weight and loose 300 grams of battery/motor(slightly smaller motor)
bringing the AUW to 1.6 kg (56 oz) and loading drops to 12.2 Oz/sq.ft

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Old Oct 12, 2009, 01:15 PM
1400 watt RW Zephyr
matwelli's Avatar
Taranaki New Zealand
Joined Sep 2003
1,336 Posts
second interesting fact

I used 1.34 cans of 3M90, 479 grams in a can (label says 500) so all up sprayed 641 grams of 3m90 on this wing

After 1 day drying AUW is 190 grams over the bare EPP weight

Need to do another wing, double check results, but 190 grams for 662 square inches seems reasonable to me, esp as I quad wraped under the batteries and double wraped over them
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Old Oct 18, 2009, 12:28 AM
1400 watt RW Zephyr
matwelli's Avatar
Taranaki New Zealand
Joined Sep 2003
1,336 Posts
Done !

Not real proud of the covering - me and covering dont see eye to eye.

My Daughter was covering some books for school, with an African scene, and we though, hey why not put a panel on each wing - didnt come out too bad at all.

The Elevons and motor/prop cutout are done in red, as thats all you can see when flying directly away, so hpe it helps with visability, as thats the only prob with the white/black on my Lightning 36, it diasapears easily when flying directly away.

All up Weight 1697 grams , lets call it 1700 grams, or 60oz , still not sure about throwing this one, its alot of weight, and its also a large wing

Ended up balancing on CG (10 inches/ 254mm) with no extra lead, and with two 3S 2500 batts.

Has just on 1:1 thrust with the waypoint 3014-16T motor and 10 by 5 prop. on 4S (batts comming) thrust will increase to 2.4 kg (84 oz)


Now just the maiden to do......
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Old Oct 18, 2009, 05:42 AM
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LOL Ive been doing the red TE and cutout on the last 3-4 wings I did. I dont know if it helps as I rarely fly my own builds......

Looks nice.....Its nice to involve the kids.....

Any tips for wrapping that curved cutout?
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Last edited by Atom1025; Oct 18, 2009 at 05:52 AM.
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Old Oct 18, 2009, 07:36 AM
1400 watt RW Zephyr
matwelli's Avatar
Taranaki New Zealand
Joined Sep 2003
1,336 Posts
Quote:
Originally Posted by Atom1025
Looks nice.....Its nice to involve the kids.....

Any tips for wrapping that curved cutout?
Tks Adam

Its hard not to involve em, Daughter wants to do the 3M90 on the next one, and is asking is we can go halvies on the profits if she builds one and sells it - shes 12 years old !

Curved cut out - yes, made a mess of the riteweave , didnt plan it well, so soaked the whole area in extra 3m90, then when it had dried and before covering, I got some document laminating film, and did the curve with that, really cooked it on (about 300F I think).
It tidied up the curve real nice, and the mono sticks well to it
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Old Oct 18, 2009, 11:49 PM
Crashing into the sky!
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Auckland NZ
Joined Aug 2007
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Use glass cloth on the rounded cut out, Spray the foam with 90, give it a few minutes to get tacky, lay glass cloth around the "flat" of the cut out, then Hossssee on the 90 and work the glass cloth around the upper and lower surfaces with ya finger before it gets tacky, if it starts getting tacky, spray some more 90

Definetly works best if ya do the cut out first with glass cloth, give it an hour or so to get touch dry, then let rip with the Riteweave over the rest of the wing.

Im no expert, but thats whats working at the moment.. Even still doing the monster rounded cut out on the TV 36 was a pig
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Old Oct 19, 2009, 12:28 AM
Fly me to the moon...
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I didnt plan ahead.... I did the top first, relieved every 1/4", 1/8" overlap and wrapped it. Followed by facing the flat with a precut piece. The reliefs is actually what caused the issues. I should of just worked it....

It turned out all right but I would of preferred better as it was a client build. I love the look of the fancy cuts and tapering the prop slot but IMHO its to much work for me. Clean square cuts get me predictable results every time.

Its nice though to compare notes for others....

Adam
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