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Aeromaster

Simplified version of the classic biplane

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Nigel R05/04/2020 00:43:10
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Aileron have yet to be tidied up and faced.

Nigel R06/04/2020 09:14:43
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Only a short spell actively working on the build last night, getting the ailerons ready for facing with 1/8 sheet:

20200405_223044.jpg

the facing won't take long. Obviously I have the main panels to face at the TE as well.

I took a picture of the tail surfaces as they stand, they look just like a vanilla lump of 1/4 sheet:

20200405_223123.jpg

both are (or will be) sheeted core (1/8 x 1/4 framework) - lighter and a bit more warp resistant than solid sheet - with med or med-hard 1/4 x 1/2 along the TE, med 1/4 x 1/4 LE. Those strips add quite a bit of strength to the core. Finished with some tips from 1/4 sheet (in this case what I had handy was some 1/4 x 1/4 strips).

In case anyone familiar with the Aeromaster looks at that and thinks something looks amiss, yes, the fin is smaller than original plan - I am making the rudder wider (I like the rudder to have some authority).

Next big job on the wings will be getting the centre 9" section together. This is the bit where the cabane attachment is done. The plan is to use 1/4 ply lugs, two of them, at the leading edge, the two sides of the cabanes will have forward facing prongs to engage with the lugs, and at the rear, a cabane crossmember will have a hardwood block clamped to it, to receive a standard 6mm wing bolt:

20200405_223403.jpg

To make all that work, when making the centre section, I have to make sure I have a nice accurate slot in the ribs for the lugs, and I have to put some soft block filler around the area where the bolt will go.

Starting to make quite a stack of parts now:

20200405_223246.jpg

AndyD06/04/2020 09:21:28
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you don't hang about,i spend to much time thinking about it rather than doing it.i want to start mine but I must finish other projects first.

Nigel R06/04/2020 10:58:57
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3756 forum posts
587 photos

If only! smiley

The log is a bit deceptive up to this point Andy, I've been putting a bit of time into this on and off for a few weeks - at the rate I build it'll be another couple of months before I'm done with the wings and on to the fuselage...

Time spent thinking about projects is never wasted, and usually winds up saving time at the end of the day.

Nigel R07/04/2020 23:00:51
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587 photos

20200407_223640.jpg

Tonight's job was marking out the slot for the ply lugs, and making some ply doublers for the balsa ribs. Lots of careful measuring. Ready to assemble and glue up the structure now.

Nigel R15/04/2020 10:10:51
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3756 forum posts
587 photos

Slow week for the build, although the short sessions I put in seemed to move things on quite well.

Most of the time has been put into the upper centre section. After part-cutting the slots for the ply lugs, I got the basic structure - ribs, spars, webs and LE - assembled:

20200409_224831.jpg

Very basic jigging as usual, just a strip near TE and near LE. Providing one doesn't bend the ribs (!) - see previous tribulations with lower wing - this is plenty to keep everything nicely straight and warp free.

The balsa ribs in this section have some ply doublers to help strengthen things up. The two ribs that sit over the cabanes have been made from liteply so won't need doublers. It is probably a little overkill but won't add much weight to the whole build. My thinking is that all the ribs can help out near the LE by distributing the loads from the lugs into the wing skins and the liteply rib will sit on the cabanes and help spread any loads from those at the bottom skin to the top wing skin. I usually try not to be shy with material use around the key areas where wings attach to fuselage. Strength at stress points doesn't go amiss.

On this section I stuck in some scraps of 1/16 near the TE of the ribs, in order to keep them correctly spaced:

20200409_224107.jpg

With these in place I only had to hold the outside two ribs in place whilst doing the sheeting.

Once I had the lower sheeting in place, I added a lump of soft balsa to prevent the wing bolt from crushing the wing:

20200410_222715.jpg

and then put some pieces of 1/4 sq (ish) next to the slots, to provide some extra gluing area for the ply lugs:

20200410_223645.jpg

I also poked the knife through the lower sheeting to mark out where the slot will be made.

With that done I was ready to button up the panel with the upper surface sheeting.

Following that operation I tidied up the sheeting at the root and tip of all the panels, and I now have some panels that look like this:

20200413_222132.jpg

and this:

20200413_222305.jpg

The upper panels only need the real leading edge to be stuck on and shaped. The lower panels also need the ailerons and the torque rods to be sorted out. They are then ready for joining together.

Edited By Nigel R on 15/04/2020 10:17:22

Nigel R17/04/2020 23:57:15
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3756 forum posts
587 photos

20200417_234246.jpg

Eight foot is a fair amount of leading edge to shape.

Phew!

Nigel R23/04/2020 10:16:04
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3756 forum posts
587 photos

Been busy (re) painting the kitchen this week, not so much play time for me in the workshop sad

I got the aileron facing on and the centre section cut free; both parts neatly sanded to length. The built up ailerons have come out nice and light even though they are large (2-1/2" wide from an 8-3/4" total wing chord).

Next move is to get the torque rods - and hinges (dry) - installed.

20200422_222941.jpg

I don't know why this picture has come out all Australian.

I also thought I had a closer photo of the facing just to prove I'm actually doing something useful with the wing, as it's not obvious that I've done anything bar saw the TE in two, but I can't find it now, I think I've had a user error when using my mobile to snap a shot of my progress... Hey ho. The facing is just 1/8 sheet, which will provide just enough material to get a good taper - I'm intending to bevel both wing and aileron.

Edited By Nigel R on 23/04/2020 10:27:32

FlyinBrian23/04/2020 11:37:12
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4 photos

Beautiful building work, It's personal taste but I much prefer the two swept wings version.

Nigel R23/04/2020 11:47:44
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3756 forum posts
587 photos

Thanks Brian

Both versions look good to me, I had to pick one and this build I went for the original layout yes

If I build another I would very likely do the "Too" variant, I tend not to build the exact same thing more than once smiley

Martin McIntosh23/04/2020 15:25:39
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3332 forum posts
1178 photos

I was at a Rochester Airport event in the very early 1970`s trying out F3A and watched Ken B. and Chris Foss doing freestyle with their Aeromasters. I remember thinking at the time, `I hope that guy does not decide to take up F3A`.

They were flying the double sweep version and I got Ken to send me a plan. For some reason I never got past cutting out the ribs; I can only think that F3A got in the way of building it.

A club mate has one with a 61 in it but it appears to me to be a rather smaller version than the ones I watched.

FlyinBrian23/04/2020 18:08:01
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Posted by Martin McIntosh on 23/04/2020 15:25:39:

I was at a Rochester Airport event in the very early 1970`s trying out F3A and watched Ken B. and Chris Foss doing freestyle with their Aeromasters. I remember thinking at the time, `I hope that guy does not decide to take up F3A`.

They were flying the double sweep version and I got Ken to send me a plan. For some reason I never got past cutting out the ribs; I can only think that F3A got in the way of building it.

A club mate has one with a 61 in it but it appears to me to be a rather smaller version than the ones I watched.

My then club was Gravesend AC who were the organisers of the Rochester model show.

That is when I first came across the AM and my first was built from a plan supplied by Ken. Adequately powered by an OS 61FSR.

Martin McIntosh23/04/2020 19:21:51
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3332 forum posts
1178 photos

Do you remember the wingspan?

FlyinBrian24/04/2020 13:25:07
612 forum posts
4 photos
Posted by Martin McIntosh on 23/04/2020 19:21:51:

Do you remember the wingspan?

Martin

It can be built in three versions.

Both wings at 48" with the top one swept.

Top wing 52" and swept - bottom wing 48" straight.

Both wings at 52" and both swept.

The plans can be found on OuterZone. see here https://outerzone.co.uk/plan_details.asp?ID=10240

Edited By FlyinBrian on 24/04/2020 13:28:41

Martin McIntosh24/04/2020 14:07:46
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OK thanks.

Do you know if the plan can be `tiled` please?

Edited By Martin McIntosh on 24/04/2020 14:53:38

Nigel R24/04/2020 23:34:32
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3756 forum posts
587 photos

Isn't the tiling something that acrobat does?

Nigel R25/04/2020 07:53:25
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3756 forum posts
587 photos

I added the hinges for the ailerons.These are polyprop flat hinges and just need a knife slot, I use a stanley blade as it is quite thick and can be snapped to form a chisel shape.

Bevels were put on using one of my hi tech bevel tools:

20200424_215759.jpg

This should be enough movement I think:

20200424_215841.jpg

I used thin cyano to judiciously harden up the front edge of the aileron.

Now that all went swimmingly well until I came to make the last, inboard slot. As I slowly wiggled the knife blade through the reinforcement hinge block fell out sad So much for my normal careful slow building!

Some open heart surgery was needed on the underside of the wing:

20200424_205644.jpg

In context:

20200424_205705.jpg

Argh! The air was filled with delightful language for a few moments.

Anyway, the hinge block went back in place and was reglued with 'some' thin cyano. Then the piece of wing skin I had cut out went back in the hole. The wing surface will never be the same again... I filled the hold and sanded back as best as I can but there remains the harder wood from glueing the patch back in. Hey ho.

Fortunately (!) this hole is right on the inboard edge of the aileron, and, after some thought, I realised that I can rescue the situation quite a lot by making the first layer of glass tissue (wing joining) wide enough to cover my sins. And then nobody will ever know. I normally do three layers of tissue with the first being around 10" wide or thereabouts. If I make it 14" wide it covers the patch up - and will help reinforce the inboard edge of the aileron a bit.

One step back, two forward...

Martin McIntosh25/04/2020 09:36:45
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3332 forum posts
1178 photos

I too thought that Acrobat offered that normally since I have done it before, so I may persevere with it but am awaiting a reply from a club mate who can normally print off files when he is at work.

I am surprised at your very wide wing joining cloth, I only use about 2" if at all.

Nigel R25/04/2020 16:25:25
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3756 forum posts
587 photos

Martin I only use surface tissue for wing joining not that girt thick cloth that used to be sold in wing joining kits. Tissue or surface cloth adds very little weight.

A nice wide piece of that also does a great job of stiffening up the wing skin making it less fragile and more resistant to ham fisted treatment during transport and assembly.

Martin McIntosh25/04/2020 21:42:15
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3332 forum posts
1178 photos

No, I meant even the thin stuff! Good idea though for preventing knocks and bangs.

I realised that the previous tiled plan I did was with an earlier laptop which has a different version of Adobe. It only took about 6hrs to download the s/w for my later wireless printer to an older one. What happened to plug and play?

As I thought, my mate is working from home and has no access to his plotter.

Only about 25 A4 pieces for page 1 of the plan so this should be interesting to do.

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