Perfexion Build Along Thread

rc4metoo · Mar 19, 2006, 07:36 PM

Hello fellow foam 3D-ers,

I would like to do a build along thread for my new design www.RippinFoamies.com full-fuselage indoor 3D bipe that I call the Perfexion. I have pioneered some novel construction techniques that I would like to share. Enjoy!

I'm not a kit builder of foamies. I would rather buy $60 of foam and make a dozen foamies. This winter I have completed 8 foamies and this will be nine.

The Perfexion is my newest design and is built from plans. I get the full size prints done at Kinkos. I then transfer the prints to posterboard to make templates. The best way to do this is to use acetone. I get my acetone at Home Depot. I get my posterboard at Staples. Both are very inexpensive.

Lay the plans face down on the posterboard and wipe the back of the paper with acetone. Like magic it transfers the print to the posterboard! Check out the photos.

Once the plans are transferred, cut out the posterboard. The posterboard I get has the thickness of a poker card. Cut out all the parts. See photos.

I also use the posterboard for painting templates. See photos!

More to come.

JC

rmgmag · Mar 19, 2006, 07:45 PM

Looks good so far. Keep 'em comming.

rc4metoo · Mar 19, 2006, 07:49 PM

My full fuse concept is build using two symmetrical sides and a top and bottom former. Why full fuse? It is a lot stiffer and stronger than the typical X-type fuse that most shockies use. Also, I find that the full-fuse bipes I build roll better - more axial. I think they look cooler as well!

My fuse concept starts with the two sides being stacked directly on top of each other (see photo). I hot glue the front and back. You have to use hot glue for the flexibility. I just deposit a small blob and then smear it out flat.

This makes the fuse an envelope where you can insert the top and bottom formers.

Now that I have all the foam parts cut out it is time to paint. Better to paint while everything is flat! I use posterboard stencils and Krylon Fusion paint. Fusion dries almost instantly so the painting step is very quick. Just position the stencils and spritz on some color.

See photos.

More to come!

JC

rc4metoo · Mar 20, 2006, 07:12 PM

I got another hour in on the project today.

The first thing I did was to add the formers to the fuselage. Looks like the CAD program worked since everything fit!

Next I added a .8mm x 3mm carbon fiber leading edge to the wings to keep them straight. I hot glue them using dabs of glue every inch or so and then tape. After taping I go over it with a warm iron to "set" the tape so that it never pulls up.

Next I beveled and taped on the ailerons and then joined the elevators and stab with tape.

I glued in the stab/elevators to the fuse and then taped on the rudder. Now she is starting to look like an airplane! I then did a trial assembly to see if everything fit. It did!

I then mounted the motor mount and calle it a night. See photos below.

JC

rc4metoo · Mar 20, 2006, 07:17 PM

Pre-assembly or what I call the "pay-off" moments when she is coming together!

JC

AirNerd · Mar 20, 2006, 07:25 PM

Awsome!

you gonna post plans?

rc4metoo · Mar 20, 2006, 07:49 PM

Quote:

Originally Posted by AirNerd

Awsome!

you gonna post plans?

The plans for the Perfexion are not ready for release yet. I need to clean them up a little. I may let some go free in exchange for a beta build and test on Ezone if you are interested.

I also have plans available now for my "Football" design (see photos). I'm trying to sell them on my website: www.rippinfoamies.com, but nobody is buying

. I can let Football plans, stencils, and manual go now for buiders/testers interested in doing builds, photos, and videos on Ezone. Just send me an email if you are interested: john@rippinfoamies.com.

JC

Just ShootMe · Mar 20, 2006, 08:33 PM

I have seen John’s planes fly, and Perfection is the word for them! He does not stop designing them until they fly perfectly in all attitudes. The Perfexion is poetry in motion when it is doing rolling circles.

rmgmag · Mar 21, 2006, 08:34 AM

Are there any formers or supports inside the fuselage?

rc4metoo · Mar 21, 2006, 02:24 PM

Quote:

Originally Posted by rmgmag

Are there any formers or supports inside the fuselage?

Hello rmgmag,

No, just formers at the top and bottom are all that is needed. The resulting box structure is stiff and straight.

JC

rc4metoo · Mar 21, 2006, 06:48 PM

Quote:

Originally Posted by Just ShootMe

I have seen John’s planes fly, and Perfection is the word for them! He does not stop designing them until they fly perfectly in all attitudes. The Perfexion is poetry in motion when it is doing rolling circles.

Thanks..er...Dick, right? I need to post some video, but don't have a video camera yet.

Tax refund expected soon maybe I'll be able to get with it.

JC

rc4metoo · Mar 21, 2006, 07:02 PM

Mostly shocky bits work tonight. A little tedious, but you can use these parts over and over again. The bits on my proto Perfexion are on their...lets see...sixth airplane.

See the photo captions below for my progress notes.

JC

rc4metoo · Mar 21, 2006, 07:07 PM

A little more work and a trial assembly for the "payoff" moment.

JC

AirNerd · Mar 21, 2006, 08:01 PM

Very very nice JC.

rc4metoo · Mar 22, 2006, 06:56 PM

I finished the Perfexion up tonight with a small amount of work. I am happy to report that everything fit and only a couple of minor changes to the CAD plans will be made.

I am super jazzed about completely hiding the RX in the fuse for the first time. I am also anxious to see how those new super light BMS-303 servos work from Bluebird. I also developed a way to hang some wheel pants on the gear legs that worked out pretty good.

She looks really nice and came out at about 6 ounces. I'll be test flying this Friday.

See captions on photos for details.

Best regards,

JC

Mar 19, 2006, 07:36 PM	#1
rc4metoo Foam Flyer Join Date: Sep 2001 Location: Michigan Posts: 266	Perfexion Build Along Thread Hello fellow foam 3D-ers, I would like to do a build along thread for my new design www.RippinFoamies.com full-fuselage indoor 3D bipe that I call the Perfexion. I have pioneered some novel construction techniques that I would like to share. Enjoy! I'm not a kit builder of foamies. I would rather buy $60 of foam and make a dozen foamies. This winter I have completed 8 foamies and this will be nine. The Perfexion is my newest design and is built from plans. I get the full size prints done at Kinkos. I then transfer the prints to posterboard to make templates. The best way to do this is to use acetone. I get my acetone at Home Depot. I get my posterboard at Staples. Both are very inexpensive. Lay the plans face down on the posterboard and wipe the back of the paper with acetone. Like magic it transfers the print to the posterboard! Check out the photos. Once the plans are transferred, cut out the posterboard. The posterboard I get has the thickness of a poker card. Cut out all the parts. See photos. I also use the posterboard for painting templates. See photos! More to come. JC Attached Thumbnails Lay plans over posterboard face (ink side) down and wipe with acetone. 22.8 KB · Views: 268 Like magic the plans are transferred to the posterboard. 26.8 KB · Views: 228 Easy to cut out posterboard templates. 44.0 KB · Views: 259 I also do paint stencils out of posterboard. See above. 45.5 KB · Views: 298

Mar 19, 2006, 07:49 PM	#3
rc4metoo Foam Flyer Join Date: Sep 2001 Location: Michigan Posts: 266	Full Fuse My full fuse concept is build using two symmetrical sides and a top and bottom former. Why full fuse? It is a lot stiffer and stronger than the typical X-type fuse that most shockies use. Also, I find that the full-fuse bipes I build roll better - more axial. I think they look cooler as well! My fuse concept starts with the two sides being stacked directly on top of each other (see photo). I hot glue the front and back. You have to use hot glue for the flexibility. I just deposit a small blob and then smear it out flat. This makes the fuse an envelope where you can insert the top and bottom formers. Now that I have all the foam parts cut out it is time to paint. Better to paint while everything is flat! I use posterboard stencils and Krylon Fusion paint. Fusion dries almost instantly so the painting step is very quick. Just position the stencils and spritz on some color. See photos. More to come! JC Attached Thumbnails Full fuse is make from two halves joined at the ends with hot glue. Forms an envelope. 43.0 KB · Views: 255 I like elevators with a thin connection instead of the large one-piece elevator usually seen on foamies. I hot glue a piece of 1.5-2.0 mm carbon fiber rod between the halves. It works very well! 37.6 KB · Views: 302 Parts all painted with Krylon Fusion. A little goes a long way. I always use too much and this is true here. Just a mist is all you need for very nice color. 56.8 KB · Views: 320

Mar 20, 2006, 07:12 PM	#4
rc4metoo Foam Flyer Join Date: Sep 2001 Location: Michigan Posts: 266	Taping it together I got another hour in on the project today. The first thing I did was to add the formers to the fuselage. Looks like the CAD program worked since everything fit! Next I added a .8mm x 3mm carbon fiber leading edge to the wings to keep them straight. I hot glue them using dabs of glue every inch or so and then tape. After taping I go over it with a warm iron to "set" the tape so that it never pulls up. Next I beveled and taped on the ailerons and then joined the elevators and stab with tape. I glued in the stab/elevators to the fuse and then taped on the rudder. Now she is starting to look like an airplane! I then did a trial assembly to see if everything fit. It did! I then mounted the motor mount and calle it a night. See photos below. JC Attached Thumbnails Fitting in bottom fuse former and gluing in with hot glue. 45.6 KB · Views: 232 Fuselage with top and bottom formers in place. 39.9 KB · Views: 285 Gluing carbon strip to front of wing with small dabs of hot glue. 51.2 KB · Views: 233 Wrap LE with thin clear tape and then "set" tape with iron set on "1". Tape will not pull up over time! 56.7 KB · Views: 268 Taping in ailerons. Be sure to leave a 1mm gap. Set tape afterwards with warm iron. 50.8 KB · Views: 241

Mar 20, 2006, 07:17 PM	#5
rc4metoo Foam Flyer Join Date: Sep 2001 Location: Michigan Posts: 266	Trial assembly Pre-assembly or what I call the "pay-off" moments when she is coming together! JC Attached Thumbnails Joining elevator to stap with 3/4" thin clear tape and then setting with warm iron. 46.0 KB · Views: 204 Elevators glued to fuse and rudder taped on! 55.7 KB · Views: 236 Motor mount glued to fuse. This X mount is "self-aligning" and about the strongest way that I have found to mount a small outrunner. 45.6 KB · Views: 242 Trial assembly to see how she is going to look. Starting to look like an airplane! 48.6 KB · Views: 274

Mar 21, 2006, 07:02 PM	#12
rc4metoo Foam Flyer Join Date: Sep 2001 Location: Michigan Posts: 266	Some more buildin' Mostly shocky bits work tonight. A little tedious, but you can use these parts over and over again. The bits on my proto Perfexion are on their...lets see...sixth airplane. See the photo captions below for my progress notes. JC Attached Thumbnails I use 1.5 mm CF rod for pushrods. I use .032 wire for the ends so that I can use Dubro Micro hardware. 43.7 KB · Views: 249 Scuff the wire with sandpaper and wrap to CF rod with thread. Glue with thin CA and kick-it. Easy! 25.0 KB · Views: 235 To connect ailerons I use strips of large zip tie. Bore out with 1/16 bit and install Dubro micro hardware. 36.8 KB · Views: 224 Glue to ailerons with hot glue and mark location for bottom linkage. 47.7 KB · Views: 219 For rudder and elevator, I cut lengths of Dubron antenna tube and slide over pushrods. These will be supports... 26.5 KB · Views: 224

Mar 19, 2006, 07:45 PM	#2
rmgmag Bob G Join Date: Nov 2004 Location: Glastonbury, CT Posts: 2,205	Looks good so far. Keep 'em comming.

Mar 20, 2006, 07:25 PM	#6
AirNerd GIMMIE FOAM!!! Join Date: Oct 2005 Location: Edwardsville KS Posts: 1,742	Awsome! you gonna post plans?

Mar 20, 2006, 08:33 PM	#8
Just ShootMe When I can’t fly anymore. Join Date: Jan 2005 Location: South Michigan Posts: 133	I have seen John’s planes fly, and Perfection is the word for them! He does not stop designing them until they fly perfectly in all attitudes. The Perfexion is poetry in motion when it is doing rolling circles.

Mar 21, 2006, 08:34 AM	#9
rmgmag Bob G Join Date: Nov 2004 Location: Glastonbury, CT Posts: 2,205	Are there any formers or supports inside the fuselage?

Mar 21, 2006, 07:07 PM	#13
rc4metoo Foam Flyer Join Date: Sep 2001 Location: Michigan Posts: 266	More building... A little more work and a trial assembly for the "payoff" moment. JC Attached Thumbnails Elevator and rudder pushrods are supported for best control response. 40.5 KB · Views: 234 Aileron horns hot-glued in. 33.8 KB · Views: 230 Aileron servo installed and .032 pushrods installed. I hot glue in my servos - works great, strips off easily for next project! 44.7 KB · Views: 278 Pay-off moment for tonight. 50.9 KB · Views: 255

Mar 21, 2006, 08:01 PM	#14
AirNerd GIMMIE FOAM!!! Join Date: Oct 2005 Location: Edwardsville KS Posts: 1,742	Very very nice JC.

Mar 22, 2006, 06:56 PM	#15
rc4metoo Foam Flyer Join Date: Sep 2001 Location: Michigan Posts: 266	Finished 'er up tonight! I finished the Perfexion up tonight with a small amount of work. I am happy to report that everything fit and only a couple of minor changes to the CAD plans will be made. I am super jazzed about completely hiding the RX in the fuse for the first time. I am also anxious to see how those new super light BMS-303 servos work from Bluebird. I also developed a way to hang some wheel pants on the gear legs that worked out pretty good. She looks really nice and came out at about 6 ounces. I'll be test flying this Friday. See captions on photos for details. Best regards, JC Attached Thumbnails I make my motor mounts out of ABS plastic that I have laying around. This X type mount works the best for Depron foamies. It is the most rugged method and simple too! 34.4 KB · Views: 223 Mount AXI 2204/54 with screws from behind. 38.3 KB · Views: 203 Thin music wire axle with "cage" bent on outside. The wheel pant will be hot-glued to cage. Wheel is Peck-Polymers free flight. 29.0 KB · Views: 204 Rough up wire with sandpaper and wrap to 1.5mm CF gear leg. Hit with thin CA and kick. Easy! and you can use it on your next 10 foamies. 35.2 KB · Views: 211

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