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Apr 04, 2005, 04:48 PM
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Building a simple depron Starlite


This is StarCessna400.

A few weekends ago i invited some friends to eat a pizza at my home, one

of they is a newbie (Carlos Bruschi) so I build a plane for him.

In fact, it was intended to be a Starlite, but in the final stages of

building I made a different tail, so a friend called it StarCessna, ant

there it is.

The model was designed to use inexpensive 400-sized motors from a local

factory and 1400mAh 7,2V LiIon or 650mAh 8,4V NiMh battery.

Bruschi take photos of the construction, taking a special care with the

less obvious steps.

The model ascends quickly and flights with less then half power, and is

very easy to control, as a proof that a direct-drive 400 size motor is

good enough for this kind of model airplane.

Construction taken some pieces of 2mm and 4mm depron and some other

materials available on local food stores.

Flight equipment are simple and cheap.

Technical specification:
Length: 56cm
Wing span: 1m
Wing chord: 15cm
Wing area: 15dm2
Weight RTF: 320g
Wing load: 21,3g/dm2
Motor: PM101TR (400BR)
Prop: GWS 5x3
Battery: LiIon 1400mAh 7,2V
Receiver: GWS R6N
Servos: 2 GWS Pico
ESC: ICS50 modified to 15A, GWS ICS300 is fine

Material:
1/4 sheet 2mm depron
1/4 sheet 4mm depron
1m of 1mm steel wire (for links)
30cm of 2mm steel wire (para landing gear)
1 pair of foam wheels
6 wood ice cream sticks for motor mount, dihedral and tail skid
3 30cm bamboo stick
3 hot melt glue sticks - thin
3m color packing tape
1 cubic EPS block with 5cm sides
2 nylon tie-ups
1 old plastic card
2 soft drink tubes
3 rubber bands
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Apr 04, 2005, 04:50 PM
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Take a 4mm depron sheet, one permanent marker, rules, etc...

If you have a 100% plan printed, cut the parts and use it as template.

Otherwise, draw a copy of plan with marker on depron sheet.

Cut the parts with knife.
Apr 04, 2005, 04:52 PM
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Glue the parts, leaving roles for links. I used the soft drink tubes to guide the links, because it is cheap, light and the wire works smooth inside these tubes.
Apr 04, 2005, 04:53 PM
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After that I made Z bends on the 1mm link wires.
Apr 04, 2005, 04:55 PM
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Z-bend done...
Apr 04, 2005, 04:58 PM
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The hords are made from magnetic card, cut as this.

Make a role with a sharp tool.

The horn must be tight on link wire.
Apr 04, 2005, 05:01 PM
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Cut holes on rudder and elevator to place the horns, insert the horns and fill with glue both sides.

Well, the horn is ready, repeat the procedure for the other horn.
Apr 04, 2005, 05:02 PM
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The landing gear is made from 2mm wire folded as shown. The weels are keep in place by two pieces of rubber tubes from a wire glued with CA.

The landing gear is inserted in the plane belly and glued inside the EPS block. This is simple and strong enough for the weight.
Apr 04, 2005, 05:04 PM
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The motor mouting is a pair of icecream sticks with a bamboo stick on the sides to prevent rolling. The motor is kept in place by two nylon tie-ups.
Apr 04, 2005, 05:05 PM
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The fuselage was done, and weights only 150g with motor and links.
Apr 04, 2005, 05:08 PM
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Next stop... the wing...

I call it "Schultz" construction, or something like "Anyway" constructor when translated to english.

Start with 10 wing ribs made of 4mm depron 4mm, and a 2mm depron sheet.

The width must be the wing span and the height twice the wing chord plus
the thickness.

Draw a horizontal line marking the leading edge of the wing, after that mark vertical lines to wing ribs and dihedral.
Apr 04, 2005, 05:10 PM
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To make the leading edge I place packing tape on the other side of the sheet, and use a pen back to emboss the curve before folding the depron.

I glued 3 icecream stick making the dihedral angle.

These sticks are glued inside the wing ribs, with a foam block in the
front for reinforcement.

The pictures tell the history...
Apr 04, 2005, 05:13 PM
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Even more glue...
Apr 04, 2005, 05:14 PM
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Now cut the trailing edge with a knife to remove the excess


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