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Just another Ballerina

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Chris Barlow12/01/2016 01:21:51
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1858 forum posts
1266 photos

Material shortages have caused a few delays in the Ballerina build but today I managed to get the missing 1/32 ply for the doublers. Unfortunately the wing for the Vulcan was on the bench part sheeted so had to finish a bit on that first.

Having cut the doublers I used EvoStik spray contact adhesive. I quite like the spray as it's very easy to get a thin, consistent coat on both sides. I sprayed one coat on both & let it fully dry before spraying another coat. It has 2 coats because the first soaks into the wood a lot.

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All 4 doublers (BEB wink  were then carefully positioned and pressed down. To prevent the contact adhesive from cupping the fuselage side the two pieces were laid on the bench and my fuselage jig placed over the top of them. The base is 3/4 ply so is quite heavy.

Since I had the jig out and the Ballerina sides on the wrong side of it I'm sorry to say I then built up the Vulcan fuselage and clamped it in the jig! I promise I'll get more progress on the Ballerina tomorrow! blush

Chris Barlow12/01/2016 23:20:21
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1858 forum posts
1266 photos

Tonight the motor mount was positioned and marked out. My engine will be mounted inverted.

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The holes were marked with a fine 0 point phillips screwdriver. This has the advantage of being almost exactly the same size as the holes in the mount plus it marks a lovely cross in the plywood.

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These were then drilled to take M4 captive nuts which were gently pressed in with a 16oz claw hammer and secured with a little cyano. (Shown after assembley!   )

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The positions of the formers were glued with a line of aliphatic then the whole fuselage assembled in the jig Starting at the front end working backwards former by former.

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Making sure F3 and F5 are square to the cockpit floor

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The great thing about aliphatic is that there's loads of time to adjust and setup the whole fuselage before the glue starts to set.

The grid vinyl sheet you get with the Slec jig comes into it's own here. The fuselage is lined up on the grid using centre lines marked on the formers and a former, in this case F2 is lined up across the jig. As long as the centre line and cross lines still line up at the tail your fuselage will be straight!

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Now it's all left for the glue to set!

Edited By Chris Barlow on 12/01/2016 23:21:28

john stones 112/01/2016 23:33:38
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10757 forum posts
1481 photos

I need to buy or make a fuzz jig, all in as a job lot and straight smiley

No building for me today, been out pricing jobs and electric and heating was off when I got home, all sorted by 7pm though.

John

Biggles' Elder Brother - Moderator12/01/2016 23:41:29
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15748 forum posts
1460 photos

I think the fuselage jig was one of my "smart buys"! Nice description of how to use it best there. It really does make getting a straight fuselage so much easier.

BEB

Craig Thomas13/01/2016 00:52:56
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478 forum posts
161 photos

Excellent progress. I can't wait to get to the fuselage. I am due a fuselage jig. When I subscribed to rcme it was part of the deal. I'm still waiting. Home it shows up soon.

Chris Barlow13/01/2016 04:07:50
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1858 forum posts
1266 photos

Definitely worth having one John. The angle clamps are surprisingly strong!

BEB, for some reason I read the instructions to it when it came. Must have been bored or no RCM&E in the bathroom! Very simple and descriptive with a few trick to setting it up quickly. Hope yours comes soon Craig you'll build everything in it once you have one!

So, 2am and insomnia has got the better of me, probably due to thinking of the glue drying or getting started on the wings! Sneaked downstairs and slipped on some jeans and a fleece jumper, coffee made and out to the workshop. 5 minutes later the heater has it up to a comfortable 17 degrees, it's 4 degrees outside and trying it's hardest to snow!

The fuze was glued up around 8pm so it's been drying for 6 hours already and the yellow aliphatic has turned almost clear so I cut up some 1/8th sq spruce then took the fuze out of the jig. Made a paper template of F5 and F10 but 1/8th oversize so it included the positions of the stringers. The templates were matches to the formers and the positions of the stringers marked out. The stringers were then pinned in position dry and checked for straightness.

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Note the top centre stringer is tacked in position with cyano gel because I simply didn't have enough thin pins!

Once I was happy with the positioning of the stringers I made sure they were all pulled down to the formers and wouldn't move by wrapping some masking tape around them and securing to the fuselage sides. Another check and a couple of minor adjustment then I ran a small blob of Superphatic between each stringer.

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I then spread the superphatic all around the joints including inside the fuselage on the underside of the stringers with a paintbrush. I'm always wary when using spruce as it seems to repel glues. The best I've found for spruce is either very thin cyano if the joints are good and not too porous or superphatic.

I also had a quick planing and sanding session on the Vulcan Fuselage with which the Ballerina is sharing the bench.

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Biggles' Elder Brother - Moderator13/01/2016 11:34:09
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15748 forum posts
1460 photos

How do you sand stuff and still have the place looking like you could eat your dinner off the workbench?!

Mind you - if I tried sneaking down at 2:00am to work on model I think Mrs BEB would ensure that I would be eating my dinner off the workbench!

BEB

AVC13/01/2016 12:43:32
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539 forum posts
147 photos

Hi Chris

This fuz looks good, but I have a question: shouldn't you have made the front deck before gluing the back stringers? The front deck extends to F5, but now F5 has the spars glued...

Chris Barlow13/01/2016 12:49:20
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1858 forum posts
1266 photos
I noticed on the drawing that the front turtle deck around the cockpit ends butted up to the stringers. I'll add a strip of soft 1/8 Sq balsa to the front of F5 to give it something to glue to.
I wouldn't put the stringers on top of the front deck otherwise there will be a step in the fuselage. The will be a slight step as th deck is 3/32 and the stringers 1/8 IIRC but that will sand out.
AVC13/01/2016 13:06:18
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539 forum posts
147 photos

Ok, that's an option

I think that what Peter Miller did was to extend the front cover behind F5, and then cut it where the stringers are located. Then the inter-stringers pieces were added to the same length.

The photo is not very clear but I think that this is how it's built

Peter Miller13/01/2016 13:59:52
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Posted by AVC on 13/01/2016 13:06:18:

Ok, that's an option

I think that what Peter Miller did was to extend the front cover behind F5, and then cut it where the stringers are located. Then the inter-stringers pieces were added to the same length.

The photo is not very clear but I think that this is how it's built

Yed, but it is all purely cosmetic so you can do it any way that you like. I usually have to add a little bit of wood where two turtle decks meet but with strintgers it is simpler just to extend the front deck back a abit.

McG 696913/01/2016 14:06:13
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2711 forum posts
1016 photos

Hi Chris,

I really get jealous about your build speed... while on a Vulcan as well... ppfff.

I'm also wondering how I'm going to build mine 'straight' without a jig? I'll probably have to construct one... sad

Great blog !

Cheers

Chris

BRU - BE / CTR Jig Control

john stones 113/01/2016 19:23:46
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10757 forum posts
1481 photos

My you don't hang about do you, sneaky little method of pinning your spars in there, can I borrow your pins when it's dry wink

John

Supposed to be a cheap model this..now I've a jig to buy and pins sad

kc13/01/2016 19:37:34
6078 forum posts
169 photos

Well I will show you my fuselage jig made from odd scraps of timber - I will put it on a the prima Ballerina thread if anyone is interested.

McG 696913/01/2016 19:52:20
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2711 forum posts
1016 photos

Yes please, kc.

... show it to the 'greenies'...

Cheers

Chris

BRU - BE / CTR Prima Ballerina & Greenies Control

 

Edited By McG 6969 on 13/01/2016 19:52:50

Martyn K13/01/2016 20:42:39
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4998 forum posts
3658 photos

Love your blogs Chris - following

Chris Barlow14/01/2016 17:44:55
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1858 forum posts
1266 photos

Thanks Martyn. I know a lot of people read the blogs and don't necessarily comment because most of the time there's no need to say anything! If just one person steals an idea or trick and uses it on their own build then it's worth it! I've stolen plenty of ideas from other blogs, including yours! wink

 

Chris, it may seem like fast progress but really it's still lots of hours of work, I just do it late into the night!

Nothing done last night though as I had to go Ice skating! Don't ask, it wasn't pretty!

So in an effort to forget that embarrassment there'll be lots of building tonight!

Edited By Chris Barlow on 14/01/2016 17:45:30

Craig Thomas14/01/2016 18:16:41
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478 forum posts
161 photos
I'm on my first of 4 night shifts tonight Chris so I'll be checking for your updates throughout the night. 😩😩😩

Edited By Craig Thomas on 14/01/2016 18:17:19

Chris Barlow15/01/2016 04:02:18
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1858 forum posts
1266 photos

After removing all my thin pins from the fuselage I have made a start on the first wing half. I started by cutting and gluing up the undercarriage blocks. The main plate was assembled from 1/8th ply as drawn. The beech block was replaced with a lamination of 1/8th ply then 2 layers of 3mm epoxy sheet then a final layer of 1/8th ply all laminated together with epoxy. I have used beech and hardwood blocks for torsion landing gear before and found they nearly always elongate the holes eventually. Hopefully the epoxy plate will fare a little better?

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I also cut the dihedral brace and from that made a dihedral template for the root rib.

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Starting on the actual wing I cut and pinned down all the 1/16th parts including the underside cap strips. Onto them I pinned the 1/4 sq spars and ribs. The top spars were then fitted and the false 1/8th leading edge cut and planed to the correct angle. This was done by pinning it to the plasterboard sheet alongside a 2' rule to keep it straight and then the angle planed with a David plane. The strip was unpinned several time to check the angle and size until I was happy with it.

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The sheer webs were also cut to an accurate width and height making sure they were square.The advantage to assembling the wing dry without glue is that the sheer webs can be cut and ready for fitting, the square ends ensuring that all the ribs are square to the spars.

The entire wing was then disassembled , aliphatic applied to the bottom spars and assembly began again! The ribs were pinned in place, glued only to the lower spars. The top spar was then glued in with aliphatic and then the sheer webs glued to the spars. With the ribs now square the trailing edges of the ribs were pinned in position to the board and a line of superphatic run where they touched the 1/16th sheet and caps below.

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The lower leading edge sheeting was then pulled up to the ribs and glued with thin cyano. The undercarriage blocks were glued in with aliphatic. To aid locating the centre of the hard block I have drilled a small pilot hole through to the underside of the wing.

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The false leading edge was the fitted and glued with thin cyano for speed.

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Before I forgot I threaded a pull through through the servo wire holes and tacked the servo end to the lower spar with a small spot of cyano. I've put pull throughs in before and lost the end inside the wing!

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With the lower assembley of the wing complete I started on the "D" box skin. The top of the spars, ribs and leading edge were sanded flush then coated with a line of aliphatic. Then the 1/16th sheet was located on the spar with 3 pins to prevent it from slipping. The entire length was then secured with clothes pegs, lots of them. The rest of the sheeting was pinned to the ribs, working forwards to the leading edge.

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I have lots of clothes pegs, and they're not for the washing!

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The aileron trailing edge was then glued in along with 1/4" thick blocks for the hinges.

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Finally to finish the evening the triangular brace was fitted next to the aileron opening.

 

Edited By Chris Barlow on 15/01/2016 04:16:09

Chris Barlow15/01/2016 04:09:57
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1858 forum posts
1266 photos

No building tomorrow as it's my wifes 40th birthday party and I'm told I have to celebrate it with her crook There will be words if I disappear into the shed!

With the "D" box complete and dry I'll lift the wing and have a look to see if I missed anything before sheeting the remainder of the wing. The disadvantage of fitting all the lower sheeting is that it covers the plan and you have to remember what goes where! The slots for the brace will be cut then it'll be time to start the other half.

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