Do it Yourself Tapered Rudder Ribs

Milling Aviation Grade Lumber from the local Box Store!

Cutting Rudder Ribs

The Epoxy Soda Can Trick

Team MiniMax "Epic" design study

Blocking out the Rudder

The Writings of Jon becomes a VLOG....

I'm going to try to log my progress with video's in addition to stills now. 

Making mistakes with your Home-built Plane

Laminating a Wood Spar

More Vertical Stabilizer Supports

Builder Log Spruce Juju

Latest photo for Spruce Juju is the vertical stabilizer.  This shot was just after I epoxied the gussets in place.  It's been many weeks since I worked on the plane.  But with warm weather I have felt new energy and a resurgence of interest in this project.


Still waiting on the complete set of plans from TEAM.  Since they are still building the prototype I figure I have to be patient.


For those of you that are just entering the blog.  This started out as a TEAM Hi-max and has since grown into a new two place side by side design called the Epic Sport.  Every minimax design uses the same ribs so I didn't have to redo any of that work.  I did have to build a different tail.  This tail design comes from the AeroMax line.  It differs from the Minimax and HiMax mainly because it has laminate bow's at the tips.

Images from the Past

 I received an email from Mary Painter this week.  Mary's folks Jack and Ruby Painter were my God parents and also part owners of the plane my dad had when I grew up.  You've read often about my musings about our old airport Taylor Aviation.  Unfortunately I just didn't have many pictures left of the old place.  But Mary has lot's of photo's and she sent these.  Above was most of the family friends, and crew that helped us with the 1986 Airshow.

 Above spectators to the Airshow including my baby sister Sarah lower left, aka Squeeker.

 Above the Stinson as it looked when the club bought it.  Notice the original  round wingtips and below you can see the drooped tips that they added later to improve stall speed, take off roll and cruise. Personally I always thought the plane looked nicer with the stock wingtips.

Don't sue aviation over me....

Dear Family and People of the World,

 

First I am not planning to check out any time soon, I love my life.  However, if I should crash any airplane and especially any experimental airplane like the one I am building.  Please, please, please, do not sue anybody over it.  If I kill myself in an aircraft, let the responsibility be mine alone and die with me.

 

I hold the designers of airplanes in the highest regard and would roll in my grave if somebody sued one over me.

 

The only people who win anything in those stupid lawsuits are the doggone lawyers, between them and the union's they've crippled general aviation in this country.

 

I love aviation and I love my country.  Good American's take responsibility for their own actions and they don't frivolously sue others for personal gain.

 

If a man goes up in a machine and buys the farm, well it's his right to do so.  He knows the risks, as I know the risks.  Just dispose of my body in any way that seems fitting and take solace in the knowledge that I checked out doing what I love and as soon as I get to heaven I'll likely check into the flying scene, if they have one.

 

With Love, Sincerity, and all God's Blessings,

Jon

Tapered Rudder Ribs and Airbike control mods

I slept in this morning!  Still managed to spend 30 minutes in the barn though before work.  I tapered two of the rudder ribs into an airfoil shape.  I searched around the barn for something that had a nice arc to use as a template.  Ended up using a wing rib!  The arc on the rudder is the same arc on the top trailing edge of the wing.  Turned out pretty nice.

 

An Airbike distributer in England was kind enough to send me some of the Airbike pushrod control drawings (see attachment).  This is closer to what I want to do with my plane.  The only drawback I can see from leaving the Teleflex cables behind is I won't be able to have flaperons and I won't be able to reflex the ailerons.  I gather the plane cruises a little faster with the Aileron's reflexed (they say three or four knots faster).  As far as flap's go, it simply doesn't need them.  Most of the folks that fly these say that they never put the flaps down.  They create a lot of drag and marginal lift and the design is already low mass and draggy to begin with, all that is needed to slow down is to reduce power, even in a shallow dive.

 

It's kind of hard to get Airbike plans in the USA because the damn lawyers have ruined it.  Personally I think it's a fine little aircraft and as safe as any of them.  I chose the Hi-Max because it's more airplane-like with an enclosed cockpit etc, but the Airbike is awesome if you like being out there in the slipstream.

 

I have no idea why Wayne Ison designed the Airbike with pushrods and the Minimax with Teleflex cables.  I suspect it has something to do with ease of construction.  The Airbike is welded tube and the Minimax line is made of wood.  For some reason a lot of homebuilders shy from welding.  I personally enjoy welding and have the equipment, but wanted a wood airplane this time.  I just find wood is more enjoyable to work with.

Rudder Post and Hinges

Today I drilled a series of 1 mm holes through the rudder post for the lower rudder hinge. Turning a series of holes into a nice neat sawn line required a bit of head scratching. I ended up taking this old saber saw blade in my hand and very gently pulling it from hole to hole, back and forth till I had a shallow trench in the rudder post. This particular blade just happened to be the exact same width as the hinge. I sawed very gently for quite some time and the trench turned into a cut. Eventually the saw blade came out the bottom of the wood and the rest was easy. Happy to say I was able to attain an absolutely perfect fit! The hinge fits so snugly that I actually had to tap it gently with a rubber mallet to push it through the slot.

I initially held the saber saw blade in my hand but this was very uncomfortable so I converted a piece of scrap into a quick and dirty handle in about five minutes. This made the job much easier.

The AN hardware fits very snugly but without issues. I put the bolts in just to make sure that they would go all the way through. They fit snug enough that I actually had to turn them in with a screw driver.

I think I should probably paint these hinges before putting them into the post for good. I was considering using POR 15. That stuff is amazing.

Tool Bench, Work Table #2, and Vertical Stabilizer.

Spent my Birthday leave getting my shop prepared to build wings! In the background you can see our new tool bench which was cut down and repurposed from an old storage loft in the garage. We had enough material to make the bench top and a shelf underneath.



Middle ground you can see my second work table butting up against the first one. That board underneath is just sitting there, I’ll cut it down and make it a cross brace tomorrow morning. I still need to add the straight edge to the second table. This should be sufficient space to build the plane. Sorry about the mess!



I helped a fellow Minimax builder move shop to a new house last Thursday and he gave me his old drill press. He had just purchased a new one and didn’t need two. The old one works just fine and has a new belt. The little wedge on the right hand foreground is our table saw.



Not a whole lot of progress on the actual plane last week. I tried to build an aileron bearing rib #5 but decided I didn’t like how it turned out. I am going to build it again and see if I can do better this time. I am learning some new tricks. Every time I start a new component I am back on the learning curve, but hey that’s what this is about. Now that I have a drill press many jobs are going to be easier and neater.



Today I cut the piano hinge provided from TEAM into two hinges for the rudder. Just used a vise and a hacksaw cleaned up any burs and sharp edges with the bench sander, they turned out pretty nice. Tomorrow I’ll drill the holes in the vertical stabilizer spars for the hinges and the fuselage mounting points.



Now just saving money to build spars.

Builder Log Spruce JuJu



Left: Aluminum strait edge ruler screwed firmly down to the bench.

Right: New work bench. 1 of 2 hopefully.

Week 12

June 30, 2014

Time Spent 4+ hours

Total Time: 45 hours

Finished up the first work bench this week!  Julie and I spent a lot of time reorganizing the barn.  The hardest part was pushing the very large cast iron wood stove back into place by its chimney pipe wall penetration.  Once I get the chimney pipes reconnected we’ll have heat.  I look forward to burning wood scraps in the stove.  Next winter I’ll be able to epoxy all winter long!  You can see we have an entire quarter of the barn cleared out now for the project, now that is progress!

Picked up two yellow aluminum rulers that were 48” long (shown in photo). They were only $8.00 apiece.  Asa and I carefully wet drilled nice neat holes in them about every 8 or 9 inches. I used our longest aluminum strait edge to make sure they were lined up perfectly before screwing them down.

Dad gifted 11 prebuilt wing ribs to me from TEAM and a Teleflex cable.

Thank you Dad!

I had worried that differences between TEAM’s jigs and mine would cause minute differences between the wing ribs and my concerns were somewhat justified.  They are a little different a 1/16^th off here and a 1/8^th off there.  I think the prudent course is to use my ribs for one wing and TEAMs ribs for the other wing.  Aerodynamically I don’t think it will matter.  The outer dimensions are very close. 

The new stuff arrived undamaged.  Overall very pleased with TEAM, glad I picked the Minimax for my first plane.  David Cooper has been ever available when I needed help or advise.

I hung the new ribs up in the barn separately from my ribs.  I really like the laser cut gussets.  Shame team doesn’t just sell gussets.

One thing I can say with pride is that my home made wing ribs are cleaner and nicer looking than TEAM’s.  When you make things for your own plane you take the time to get it as perfect as possible.  Of course they have more experience than me and I suspect that my level of precision simply isn’t needed for wing ribs.  The TEAM ribs are perfectly sound and strong, nothing wrong with them at all.

I also bought some used cheap used galvanized metal conduit and some phosphoric acid.  I’ll use the acid to dissolve the zinc coating and thus rendering the metal safe to weld.  This I’ll use to practice welding this summer.

I plan to upgrade my Lincoln with a gas kit so I can MIG (Metal Inert Gas).  It can arc weld right now with a spool of fluxed wire but I think the MIG welds are stronger and look better.  I’ll get a cylinder of CO2/AR mix for welding steel and a cylinder of AR alone for welding aluminum.  The Minimax as designed does not have a lot of welding if any required but I think I’ll weld my own motor mount.  Plus I might shape my cowling out of aluminum instead of carbon fiber.

Just for fun I lofted the vertical stabilizer this morning.  I LOVE my workbench.  Having a metal ruler screwed down in combination with a carpenter square is the bee’s knees!  It’s like having a giant drafting board.  I’ll get back to wing building soon I just wanted to make something new for awhile.  After 45 hours of wing ribs, I’ve earned it. 

I still have to put the blocking into the specialized ribs for the aileron brackets and so forth.  Today I’ll go to the hobby lobby and see what their plywood looks like; I’ve heard its aircraft grade.  I’ll do a boil test with a few plywood coupons and compare it with the stuff I’ve been getting from aircraft spruce.

Next week I’ll get the materials to build the next bench.  This one will only be five feet long instead of eight feet.  I plan to bolt the two benches firmly together perfectly flush.  I can do this because I’ve put carriage bolts in all the feet of the tables so they can be raised or lowered tiny fractions of an inch with a ¼” box wrench.

Flight Design CTLS and workbenches.

Yesterday I flew the Flight Design CTLS for about an hour.  My instructor was Bob Chandler, owner of Chesapeake Aviation.  My impressions of Chesapeake Aviation are that it is very much what I expected and what I have seen at a number of flight schools.  Bob's wife Dot answers the phones and greets people at the door.  She put's in seven days a week there, I may suggest they take a couple off.  Bob was outstanding, very knowledgeable about the aircraft and he took nearly an hour showing me all of its eccentricities before we even took off in preflight.  The Citabria was sadly down for engine maintenance but it looked very nice.  Bob thinks I should get my Sport pilot in the CTLS and then get a tail wheel endorsement after the fact in the Citabria.  Then he says I can build my time for my private and so forth in my own plane. Bob thinks my plan is a good one and economical.

 

The CTLS is fast (cruise 130 mph, stall 39 mph) and it takes some getting used to.  For example we had to back way off power on the downwind leg of the pattern just to give it time to slow down enough to land. 

 

It's the first plane I've ever flown that used a stick instead of a yoke.  It's extremely sensitive and responds to the slightest control input.  Since it's a two seater when you are in the left seat you hold the stick in your left hand and right hand on the throttle, from the right seat you fly the opposite way.  Compared to the GA planes I've flown up till now the CTLS handles like a sports car.

 

The other thing that took some getting used to is the glass cockpit.  Pretty much everything was displayed on three LCD screens, engine numbers on the right screen, GPS middle screen, and then the flight instruments on the left screen in front of me.  It's fairly intuitive but still different and I struggled some.

 

The cockpit is quite roomy inside and we didn't rub shoulders like I usually do in GA planes.

 

We went up and flew out of the pattern and Bob let me make some turns and then just cut me loose.  He asked what I would like to do.  I told him I would like to head back and shoot approaches so we flew back to the airport and did a few touch and goes and then landed full stop.

 

At home I've been building work benches.  Just about finished with the first bench.  I decided to buy new wood and build from scratch because the loft stuff just isn't built flat and true enough to be considered.  Decided to use the full sheet of plywood so these project benches are each 4 x 8 and 33 inches tall.  Today I am going to pick up some carriage bolts to make them adjustable on the bottom. 

 

I still have to bring the loft storage platform in the garage down to make room for a new closet and I am still going to use the loft structure.  I am just going to make tall narrow tool benches out of it (instead of low wide work benches) to hold some of our bench mounted tools (bench sander, bench vice, etc.

 

My oldest daughter Caelynn is visiting for a few days and has an interest in Aerospace Engineering so I thought I might help her to build a wing rib, just for fun.

Bed Time Stories for Little Pilot's

 

 

So last night my son wanted me to read him a book before bed.  "Do you want me to read you a book, or tell you a story?"  At first he chose the book option but when after offering him several choices he had already heard ad nauseum he finally relented and asked for the story.  "Do you want to hear about the first man to break the sound barrier?"  He nodded.

 

I told that story to the best of my ability beginning with how many pilots and planes went up to break the barrier and many were lost.  Using my hands to gesture the shaking and the sound waves.  As we went up into the belly of the B-29 he was completely rapt.  Higher and higher, then to step across the abyss of air and space to nestle into the Bell X-1.  I made sound effects of the rockets firing and described how the plane began to shake.  And finally the massive sonic boom and the heroic safe glide down and landing.

 

He ate it up! "Tomorrow will you tell me another story daddy?"

Of Ribs, Family, and good Friends.

I put the temporary gussets on the final rib for the right wing and gingerly popped it out of the jig this morning. I've been practicing getting my angle cuts perfected so that each piece of RS-1 (1/4" Spruce square) fit's snugly against every other piece. The plans say everything can be cut at right angles but I wanted to practice my craftsmanship because in other areas of the plane that precision is required. I was thankful for all that practice on the other ribs because for this rib you have to epoxy the spruce together and not rely so much on the gussets.

Looking at the empennage, it's a lot bigger than I expected. I realize now that this too will require a work bench. I can't wait to get that built so I can carry on.

Incidentally my Easy Cutter Ultimate tool grew dull. For those of you who have this tool I can tell you it's easy to sharpen. You just remove the lock nut and bolt and the blade slides right out with the handle that is attached to it. Then I sharpened it like I would any good knife and slid the parts back together. The spring is a leaf type and is mounted firmly to the handle that supports the cutting base so you don't have to worry about it bouncing into a pile of sawdust never to be seen again. Once reassembled the cutter worked good as new. Now that I know how easy it is I'll sharpen it often.

Finally, best news ever, my dad (a pilot himself) offered to pitch in and help me out not only with my plane but also my flying lessons. Dad if you are reading this, thank you very much sir, indebted to you. He ordered me another rib kit from TEAM and set me up at Cheasapeake Aviation for an intro flight.

I've come a long way from moving some boxes in the barn and building a rib jig on a folding table. My wife (who is an aviation buff herself) is on board. I now have a friend (Peter) 30 minutes away who is building the same kind of plane and helps me in many ways and the support and wisdom of my Dad who is has been flying various types of aircraft from ultralights on up to Boeing 747's for over 40 years. Not to mention everybody at TEAM and on this forum. I am truly blessed, thank you all.