How to make an ultralight look like a Piper Cub

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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

From left to right, there are six formers: A through F.  There are two window formers, and two window eave formers, four angle gussets, and four square gussets.

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"

In the above photo, the longerons are glued using lots of clamps.  As they are bent, this will require making sure that the overall turtledeck structure stays flush to the fuselage.  You can see some big clamps along the side of the fuselage which help keep it all clamped down and square.

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.

The purpose of the stiffeners in the above photo is to prevent the bottom longerons from bending when the structure is covered with lightweight dacron fabric.  Of course, to work well, we need to add a second level of stiffeners:

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.  

more spy photos

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TOP SECRET -- EYES ONLY FOR UNDERSIGNED

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!


TOP SECRET -- EYES ONLY FOR UNDERSIGNED

To:  C.S.R.
From:  Ace Industrial Spy Service, Bob Phillips, PI, acting SPECIAL AGENT
Re:   Belite's Product Improvements ----- TOP SECRET MEMO #5


Mr. C.S.R.:

I know you are eager to get more information on the developments in Wichita at Belite Aircraft.  Well, the bizarre events at Belite Aircraft continue.  While observing from under the cedar trees in the rear alley, I noticed the owners leaving in a big hurry -- the man (James Wiebe) holding his left hand and appearing to be in great pain, with his wife (Kathy) driving their vehicle and exiting the parking lot in a huge hurry.  Whatever the problem was, I did see him return the following day, albeit with a huge bandage on the thumb of his left hand.  More on that topic at the end of this TOP SECRET MEMO.

While reconnoitering on the south side of their facility, I noticed that the UltraCub which you've asked me to investigate had been pulled outside.  Without revealing myself, I took this picture:

Belite UltraCub?  Spy photo

Since no one was around, I was able to get several more close up shots from different angles.  Here they are:

Belite UltraCub, side view

Belite UltraCub, quartering rear view

It's clear that they are planning to paint the turtledeck and rudder, It also seems that they plan on installing polycarbonate lexan in the nostalgic cub rear moon windows.  Also, they certainly plan to cover the landing gear "A" gear with fabric as well.

I am positive that the engine on this particular plane is a MZ-201, with 45HP.  This is the same engine combination that provided extraordinary performance on one of their earlier planes (see background video HERE demonstrating takeoff performance).

I also was able to get a closeup photo of the rear turtledeck detail:

Detail of Belite's UltraCub

And it appears obvious that the entire piece has been designed for easy attachment and removal.

I was startled as their groundskeeper rolled into view.  Thankfully, he didn't see me.  I went back around the corner to the north end of their facility, and was shocked to see Belite's president (James Wiebe) come outside and discuss their UltraCub project with an unidentified individual.  While I was looking (carefully and surreptitiously) around the corner of the building, Wiebe removed the turtledeck and continued the discussion.  I took several photos:

James Wiebe (Belite President) holding UltraCub rear fairing

Mr. Wiebe discusses structure of UltraCub?

Mr. Wiebe with left hand thumb in bandage?!

Concerning my observation of the Wiebe's leaving in a rush, on the prior day:  While they were outside talking, I snuck into the building and observed a dried area of blood on the floor close to the table saw.  Perhaps these events and observations are related.  If I learn more, I will let you know.

P.S.:  While I was inside their shop, I noticed an amazing paint job on an airplane under construction, and I also noticed some amazing engineering on a wing design.  More information will be forthcoming as I have time to investigate.

Industrial Espionage at Belite

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!


Following note found in Belite Parking lot:

TOP SECRET -- EYES ONLY FOR UNDERSIGNED

To:  C.S.R.
From:  Ace Industrial Spy Service, Bob Phillips, PI, acting SPECIAL AGENT
Re:   Belite's Product Improvements ----- TOP SECRET MEMO #2

SIR:  I was able to take more spy photos of Belite's product development effort.  In particular, I observed their latest development:  a highly streamlined rear turtledeck for Belite's aircraft, which appears to make a Belite look like the best single seat nostalgic cub reproduction ever, and I overhead them mumbling about expected improvements in climb rate, speed, and fuel efficiency as a result of their innovation.

While their staff was out to lunch, I was able to closely examine the prototype structure, and I can confirm that it was built from CNC cut wood formers using five layer baltic birch 1/4" plywood and aircraft quality wood longerons.  It looks like they are making impressive use of their CAD / ShopBot to create a potentially inexpensive and attractive addition to their product line.

Rumor has it that a degreed aeronautical engineer has also entered his belief as to the expectations as to drag reductions.

Build quality of the prototype was excellent - world class.

While crouched outside their shop door, I heard them discuss the weight of this innovation -- only 5 1/2 pounds as shown.

They had left the structure to dry, after application of some sort of waterproofing spar varnish, and I had my opportunity to take the photos.  I hope you can appreciate the risk I have taken to get these photos to you.

They were constantly muttering something about it being called an UltraCub -- best ultralight ever.

I also saw some other innovations.  THREE MORE ultralight innovations in particular caught my eye, but I did not have the opportunity to take photos or the time to describe the other innovations in this report.  Hopefully soon.

P.S. -------  While taking these photos, I observed three of their employees methodically walking back and forth across the runway, dragging rakes and hoes.  Very very odd behaviour indeed.  I will attempt to gain an explanation, but I emphasize:  I have never seen such an odd thing before.  Whatever the explanation, it misses my mark at this time.

((((SCANS OF SECRET PHOTOS FOLLOWS))))

UltraCub rear structure -- Belite ultralight aircraft

UltraCub rear structure -- Belite ultralight aircraft

UltraCub rear structure -- wooden formers and longerons, Belite

UltraCub rear former being glued, clamp still in place

Amazing lines on UltraCub from Belite Aircraft