How to make an ultralight look like a Piper Cub!
Well, the answer to that question is to start with a Belite and put an UltraCub Turtledeck on it. The kit costs $500. It includes all of the precut formers, along longerons and lightweight dacron fabric. All the formers are CNC cut Baltic Birch plywood or aircraft quality Douglas Fir (in either 1/4" x 3/4" size or 1/4" x 1/2"). All you have to do is cut the wood strips to the right length and use good glue and lots of clamps.
The building surface is the back of your Belite. This guarantees that whatever slight warps you built into your fuselage will be reflected in the turtledeck, guaranteeing a good fit and a good look.
In the following photos, we're using our super secret upcoming four stroke demonstrator airplane as the basis of this particular turtledeck and resultant ultracub.
The photos are very self explanatory, so I'll keep comments to a minimum between the photos. We'll start with a photo of the completed turtledeck, so you can see what you are trying to make:
|Completed Turtledeck for a Belite Ultralight airplane -- UltraCub|
Start by fitting the "A" former, the window formers, and the "B" former together. You'll need to cut off the bottom of the "A" former, unless you want to leave the turtledeck permanently attached to your plane. Cutting it off allows the former to be placed over the flaperon cables. Also check the fit of the tabs. They are a very tight fit and will need some help with your file or X-Acto razor saw to achieve a perfect fit.
|Bottom of A former is cut off as shown|
|Gluing the A and B formers along with the window former|
|Gluing the window eaves former|
|Window eaves after clamps removed; bottom longerons (1/4" x 3/4") placed and glued|
|Gluing C, D, E formers to bottom longerons|
|Gluing F former in place to bottom longerons|
|Gluing top longerons in place -- two 1/4" x 1/2" and one 1/4" x 3/4"|
|Use lots of clamps.|
|Side longerons (1/4" x 3/4") and front angle gussett glued in place.|
|Top corner longerons (1/4" x 3/4") glued in place. Longeron is fitted first to butt into corner.|
|Top corner longerons and lots of clamps -- a recurring theme.|
|1/4" x 3/4" stiffener glued to back of B former.|
|Angle gussett glued to top longerons on each side|
|Square gussett glued in place on C former.|
|Additional (sideways) top corner longerons glued in place, forming 90 degree angle longerons|
|Between Former stiffeners cut, fitted and glued in place.|
|more stiffeners on the higher level.|
|short longerons cut, fitted, glued and clamped in place.|
|90 degree square gussett on E former|
|All longerons trimmed off, view from front.|
|quartering view of turtledeck for Belite ultralight aircraft -- UltraCub.|
|view of rear of turtledeck.|
Your turtledeck is now ready to cover with Dacron fabric.