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PSS Dash-7 (DHC-7) build blog

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Phil Cooke26/10/2020 15:57:29
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2666 forum posts
1858 photos

Looking great Ben - good to see this back on the bench again!! Keen to see this one on the slopes! thumbs up

Ben-Erik Ness31/10/2020 15:48:19
26 forum posts
51 photos

More progress to report!

Fuselage is finally sheeted with balsa. I have never done a balsa sheeted fuselage before, but I'm pretty happy with the result.It's far from perfect, but when it glides past the slope nobody will notice!

The main wings are also glassed. I'm using peelply and that makes it easier to acheive a good result!

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Ben-Erik Ness03/11/2020 19:58:31
26 forum posts
51 photos

I have started on the part of the build that I have dreaded the most, building a functional detacable T-tail section. Due to the size of the fuselage (over 2m long) I need to be able to take the tail and tailplane apart for transport.

The idea is to have a 10mm carbon rod/tube that functions as a threaded rod, running inside a 12mm carbon tube in each section, pulling everything together from bottom to top. The most challenging part is to get everything together strong enough, and to mount the whole thing lined up correctly. My laser will help a lot here..

Pictures shows the tail before sheeting the tail and rudder...

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Ben-Erik Ness05/11/2020 15:28:04
26 forum posts
51 photos
Posted by Andy Meade on 04/02/2019 09:17:34:

221g doesn't seem at all bad, I'd say go with it. If you need to make another in the future, at least it's a wing, right? I know that's not ideal, but that's what I always say to myself!

I have for some time debated with myself if I should rebuild the tailplane. Well, I thought I'd have a go at it. Same construction as last time, less carbon reinforcement and much lighter balsa sheeting. My aim was to cut the weight in half!

It took me the evening to process is, and I'm delighted to finsh it at a mere 103 grams, ready for glassing. This means a reduction in noseweight of about 400 grams, and a saving of a total of 500 grams og the AUW - absolutely wort the effort!

New wing:

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Andy Meade05/11/2020 15:31:27
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2789 forum posts
717 photos

Goes to show that you should never listen to me! Great result and progress so far, keep it up yes

Ben-Erik Ness11/11/2020 19:43:07
26 forum posts
51 photos

After quite a fee hours in the production hangar, another milestone has been reached, the airframe is now glassed. To allign up the tail, and to construct a solution to make it detachable took some time but now it's all in place.

The fuse and tail is now glassed, ready for some sanding, and construction of 4 crying detacghable engine pods...

Some photos of the process and result so far:

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It has a good size...

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Glassing...

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Martian11/11/2020 20:28:50
2655 forum posts
1270 photos

That's a really unusual want to build but wow it looks great

Ben-Erik Ness11/11/2020 22:31:47
26 forum posts
51 photos
Posted by Martian on 11/11/2020 20:28:50:

That's a really unusual want to build but wow it looks great

I'd like to disagree - hotwire cutting foam and covering it with balsa or other wood is a method as old as the hills...
But it works smiley and has done so for along time!

Mike Chantler11/11/2020 23:27:14
17 forum posts

Lovely build, fuselage and wing saddle look great. Simple carbon reinforcement really appealing. But how did you get the white foam carved so well? When I've tried it, the white EPS beads go everywhere and ruin the surface.

Ben-Erik Ness12/11/2020 16:14:42
26 forum posts
51 photos
Posted by Mike Chantler on 11/11/2020 23:27:14:

Lovely build, fuselage and wing saddle look great. Simple carbon reinforcement really appealing. But how did you get the white foam carved so well? When I've tried it, the white EPS beads go everywhere and ruin the surface.

Thanks!

I use a very very sharp fishknife, with a long blade that gives me the ability to "shave" off small thin peices at the time...
https://www.marttiini.fi/Condor-Filleting-Knife23

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