Monday, February 20, 2012

Flaperon Build Manual Update

Please note: James' blog has moved to a Wordpress site. To access it, please visit http://jameswiebe.wordpress.com/. All posts have been transferred to the new site, and all new posts will only be accessible via Wordpress. Thank you for your interest!


Everyone is interested in reducing build time and building a better product.  I've been able to do that with flaperons, used on our Belite ultralight aircraft.  The time required to build a flaperon structure is now down to less than four hours per flaperon!

This assumes an easy to build wooden jig, which will hold all the ribs in place.

This is an update over our earlier manual, published just a few weeks ago.

These techniques may be applicable to building control surfaces (elevator, rudder, stabilizer, etc.) on your favorite ultralight aircraft.

At Belite Aircraft, here's how we do it.

Table of Contents
Section A.  Specifications. 2
Section B.  Materials. 3
Section C. Preparation. 5
Section D: Build Jig; Test Fit Ribs and Bushing/Droppers. 6
Section E: Glue the Main Spar. 8
Section F:  Glue the Leading Edge, False Ribs. 9
Section G: Balsa Parts. 11
Section H: Trailing Edge. 13
Section I: Trim aluminum placement. 17
Section J:  Trim and sand glue. 17
Section K:  Apply sealant to wood. 18
Section L: Covering. 19
Section M:  Check Fit to wing assembly; install control horns. 19


Figure 1.  Completed Flaperon on an ultralight plane.
  

Sunday, February 12, 2012

MythBusters and Australia

Please note: James' blog has moved to a Wordpress site. To access it, please visit http://jameswiebe.wordpress.com/. All posts have been transferred to the new site, and all new posts will only be accessible via Wordpress. Thank you for your interest!


It's time for another MythBusters moment for Belite Aircraft!

Airing in Australia today -- "Duct Tape Plane" featuring Belite Aircraft!

We've developed a great contact in Australia helping us represent our aircraft -- Peter Harlow @ Silverwings Aircraft.

I so enjoyed my time with Kari, Grant and Tory at MythBusters.  I thought you'd like a few more MythBusters pics.

Many people don't realize that the airplane I used for this episode had our base 28HP engine.  It looks like and performs like it had a lot more HP, but it didn't.  Credit our great wing, light design, and awesome 'real' airplane characteristics. 

Belite's Ultralight Aircraft at MythBusters.

Another thing that is hard to appreciate is just how much time it takes to make good television.  This particular episode took the better part of 3 weeks to film.  I wasn't even there during the last week of filming.

Grant, Kari and Tory work on the Belite ultralight aircraft, after some duct tape has been applied.



The attention usually goes to the hosts, but there are lots of folks behind the scenes who make it happen.  Each episode needs a producer, a director, at least two cameramen, a soundman, and more.  Then there's the outside riff-raff (like me) who help facilitate.

The first camerman sprints away from Tory and Grant
Since I had my experience at MythBusters, they've had quite a bit more fun.  And an accident (or two.)  The same trio I worked with (Grant, Tory, Kari) where the ones who sent a cannonball very accidently through a house near the Alameda bomb range.  Not Jamie or Adam.

Speaking of Jamie & Adam, I never had the pleasure of meeting them.  We were given a very nice tour through their facility before they showed up.  I suspect they are slightly tired of the fan attention.

My shop manager, Gene, was able to join me at MythBusters as well.  He helped ensure that everything was put together correctly, and got to help and observe in several different ways.  I couldn't do Belite without Gene, and I appreciate him deeply.

Here's Gene, sitting in the airplane.  The plane appears to be missing its wings in this shot:

Gene in a Belite Ultralight Aircraft at MythBusters


One reason our plane has been so successful is because the wings fold easily.  When Kari found out how easily the wings folded, she started dancing spontaneously, while Grant, Tory (and producer Eric Haven) looked on:
Kari Byron dances by Belite Ultralight Airplane

I hope you enjoy the episode, "Duct Tape Plane", on MythBusters.

Wednesday, February 8, 2012

Hasking and other Reflections on Fatherhood

Please note: James' blog has moved to a Wordpress site. To access it, please visit http://jameswiebe.wordpress.com/. All posts have been transferred to the new site, and all new posts will only be accessible via Wordpress. Thank you for your interest!


Hasking and other Reflections on Fatherhood

© 2012 by James Wiebe
All rights reserved

A Crying Man in the Parking Lot

The man in the parking lot of the movie theater is sitting in the driver’s seat of a red Acura, and he is heaving and sobbing and shaking in a way that expresses the deepest kind of Pain.  His torso is curled forward, and his head is down, almost between his legs, From the crooked angle of his body, he is seeing just the bottom of the steering wheel, and the dirty carpet. 

He had made it from the front door of the theater across the parking lot, to the car, making small talk with his wife about the movie they had just seen, but grieving over what he had felt.  Before the movie had started, they had discussed taking in two movies in one evening:  back to back, a rare treat for this couple.  But that idea had died, in fact it had been killed, while they were walking out of the Cineplex.  

(They had been in The Balcony, mind you, to the right of the main entrance.  Stadium love seating with Restaurant service, to your seat, while watching the movie.  Dolby and THX sound.)

He had made it to the door of the car.  He had been able to unlock the car.  He had been able to sit down.  He had been able to place the key into the ignition, and even to turn it.  He noted that the car had started.

But then, as the motor started and idled, muscles in his face began to contract, short tight ones, along the sides of the jaw.  Other muscles in his gut turned to knotted cords of tension.  They were very tight, and then they were even tighter.  Liquid flowed out of his nose, but oddly, very few drops from his eyes.

His larynx tightened as well – breathing turning to a heaving or a hasking; and his eyeballs were pushed by the blood pressure of the emotion to the front of his eyelids.  In the midst of his enormous pain, he wondered if the eyes could be damaged by so much tight heaving, hasking, pushing, sobbing, hasking.

The wife of the man was making a heathery crying of her own, just like the animal mother of a severely wounded cub – why is the cub so hurt? – will the cub stop hurting?  – What can I do? – How can I soothe? – What light sounds can be made that will ease the pain?  Can I stroke your back? – Her hand gently and very carefully moved up and down his arm and shoulder, and just across the top of his back, and then back down.  Sending a signal through his hurt, that love was there, it was very much there!, and that it was waiting for him to come back out, and that love was there.


Tuesday, January 24, 2012

How to laminate carbon fiber to plywood

Please note: James' blog has moved to a Wordpress site. To access it, please visit http://jameswiebe.wordpress.com/. All posts have been transferred to the new site, and all new posts will only be accessible via Wordpress. Thank you for your interest!


In our Belite ultralight aircraft, we occasionally make and use a carbon fiber / plywood laminate.  This makes a very nice looking and strong panel, yet is very thin.   It is capable of holding a lot of load when suspended across a frame, for instance, a seat bottom.  (Double sided applications would probably be used with other cores than thin plywood.)

I recently made some of this magic thin carbon fiber / plywood.  I documented the production steps so you can see how we do it.

In order to do this, we'll use some thick beveled glass, tacky tape, a vacuum pump and some vacuum tubing, bagging film, peel & ply film, fluffy cloth padding, epoxy, and of course, -- carbon fiber and plywood.

Let's start with a nice sheet of beveled plate glass.  We've cleaned it thoroughly (I mean it, thoroughly!!!) and have lined the edges with tacky tape.  It has been waxed, then the glass has been sprayed with film release, and I've run some plastic vacuum tubing along one edge, secured with tacky tape as well.

Warning:  carbon fiber and epoxy and glass can be nasty stuff -- always use breathing protection, along with protective gloves.  Use these instructions, as always, at your own risk.

Let's get going...

Plate glass, cleaned and prepared for use.