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Feb 04, 2015, 05:34 AM
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Sky King's Songbird


Several years ago I had done a 42" span "Bamboo Bomber" that for several reasons never saw the light of day. Shortly after, I had started an up-scaled version at 48". Again, for various reasons it ended up being shelved.

But since then, Dare/Brodak had expressed an interest in offering the Bobcat as a full kit, done as Sky King's "Songbird" to avoid any possible conflicts with "copy right infringement" with the original manufacturer. Well, the plans are pretty well roughed in and the p-type is under construction. And with Dare/Brodak's ability to get a new design into production quickly, once the model is finished and flown it won't be long before the kits for the Songbird will be available.

So, let's get started;
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Feb 04, 2015, 05:38 AM
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Starting with the Wing


The wing is undoubtedly the most complex part of the build, so we'll start there. The wing assembly is built in one piece begining with the main spar assembly that's done in 3 pieces. The rear spar is full span also, but because it tapers forward is not "pre-assembled" as with the front spar.
Feb 04, 2015, 05:42 AM
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Construction Begins with the Center Section


The center section is built up flat on the board directly over the plans. The ribs are keyed onto the main spar and center rear spar with the trailing edge, hold down bolt plate and leading edge stiffener being added once the ribs are in place.
Feb 04, 2015, 05:48 AM
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Building the Wing Panels


With the center section completed, the assembly is lifted and the main spar angled over and pinned flat on the board. The other end is blocked up to prevent it being damaged during construction. The rear spar is pinned in place.

Starting at the root, the ribs are added as fare out as the landing gear mounts which are built into the ribs and main spar. Once the mount plates are in place, the remaining ribs are added followed by the leading and trailing edges, aileron hinge spar, wingtip bow, and the servo mounts.
Feb 04, 2015, 05:54 AM
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Building in the Aileron and finishing the Basic Wing Assembly


The aileron is build into the wing assembly while it's still pinned to the board. Then once that's done, the wing is lifted from the board, rocked over to the onther panel and the process repeated to finish the basic wing assembly.
Feb 04, 2015, 05:57 AM
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Mounting the Landing Gear


The landing gear is bent up from 3/32 music wire. Then prior to fitting the struts, the bottom sheating is added to the wing. The struts are then lashed to the mount plates using either Kevlar or heavy duty nylon thread.
Last edited by P. Tritle; Feb 04, 2015 at 06:22 AM.
Feb 04, 2015, 06:01 AM
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Finishing the Wing Assembly


Once the landing gear is in place the top sheating is added and the wing sanded to rough shape. The ailerons are removed and the final sanding and shaping done.
Last edited by P. Tritle; Feb 04, 2015 at 06:23 AM.
Feb 04, 2015, 06:05 AM
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Building Up the Nacelles


The nacelles are built directly on the wing using the plans for reference to locate the formers and other components. Reference lines are drawn onto the sheeting. and once the rear formers and the keel and spine are in place, the rest will self align, so care must be taken to properly locate the formers on the sheeting.
Last edited by P. Tritle; Feb 04, 2015 at 06:21 AM.
Feb 04, 2015, 06:10 AM
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Adding the Remaining Formers and Firewall


The remaining formers and side supports are added and glued in place followed by the top and bottom side fairings.
Feb 04, 2015, 06:14 AM
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Adding the Nacelle Stringers


With the basic assembly together the stringers are added followed by the cowl fairing ring on the firewal. The other nacelle is built up the same way, then the entire assembly sanded to final shape.
Feb 04, 2015, 06:18 AM
rtibbetts
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Nice! Look forward to this one. 48ish wingspan?
Feb 04, 2015, 06:20 AM
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Building the Tail Section


Now that the hard part is done it's time to move on to the simpler things. The vertical and Horizontal stabilizers are air foiled, so shims are required to center the leading and trailing edges on the ribs and spars. The plans show the size and location of the shims. From there on it's all straight forward stuff. Then once the assemblies are completed they're removed from the board, sanded to shape and the hinges added.
Feb 04, 2015, 06:28 AM
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Building the Fuselage


The fuselage is a typical stick frame style assembly. Construction begins with the side frames, and when completed are joined by the upper and lower formers. Since there was really no good way to support the side frames to add the upper and lower cabin formers, the joining began by adding the front and rear former sections using squaring blocks to insure a good alignment.
Feb 04, 2015, 06:31 AM
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Joining the Side Frames


With the first two formers in place, the other side frame was aligned and glued in place and the bottom former and cross piece added to stabilize the frame. Then the frame was lifted from the board and the remaining top cabin formers were added.
Feb 04, 2015, 06:36 AM
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Building Up the Tail Wheel Mount


The rear fuselage former is built up and the bearing tube added for the steerable tail wheel. It's a whole bunch easier to add the tube and lash it in place before the former is glued in place then trying to work in the confined space at the tail.


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