Crazy Weird Stuff at Belite

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CSR:  You sent me that interesting email yesterday, and yes, I would be thrilled to know your identity.  I want you to know that I appreciate the steady income doing this work for you has generated for me, albeit your anonymous nature has puzzled me.  But I fear that my ability to generate this 'spy' information for you may soon be compromised.  I have taken too many risks while 'hanging' around the hangar and taking these photos.

Sigh.  The life of a spy....   I'll bet you don't have a clue how much stress this spying creates.  You really don't pay me enough...   But I digress.

(Regaining my composure)  I was able to slip into the hangar at Belite late this evening, and today, I offer you a couple of photographs which confirm your worst fears:

a)  The UltraCub / 4 stroke combination does indeed feature a flap / aileron combination which has been extended all of the way to the end of the wing.  This is certain to reduce landing speed (and takeoff roll) even further, and also provide for spritely roll control while in flight.

b)  It also features winglets.  These aerodynamic improvements look diminutive in size, yet promise to improve roll control (and wing lift, and reduce wing drag) even further.

Without further ado, here are those photos:

winglet on Belite UltraCub (Ultralight Aircraft)

Belite UltraCub (ultralight Aircraft) with expanded flaperon area and winglets

I noticed one other feature on this Belite, but it will have to wait for a future communique.  Also, I saw a sheet of paper with the price of an UltraCub kit, and it was startlingly low.

Your Servant Faithfully,

Bob Philips

4 Stroke Opposed Engine on Ultralight - Confirmed Sighting

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 #18

Mr. C.S.R.:

Thanks for calling me earlier today.  I appreciate your concern over the fact that Belite is preparing to offer a traditional opposed cylinder four stroke engine on a legal Part 103 ultralight aircraft -- this is indeed a gamechanger and will help re-awaken the ultalight marketplace.  Per your request for information, I returned to Belite's facility late this afternoon and took some more clandestine photos while most of Belite's staff was absent.

It was sweltering out there.  I can't imagine how they continue to work as daily high temperatures in Wichita are forecast to hit 107 degrees later this week... 

Also, as a side note, I was able to observe Mr. Wiebe briefly, and I noted that he now is sporting a slightly "Harry Potterish" scar on his left forehead.  What is with that man??  Between emergency room runs (a rumored six stitches on the last ER outing); welding burns; daily cuts; and odd bruises, I am amazed he still has his vision and his digits.  

I agree with your comments concerning their aircraft finishing methodology.  They are now able to create world class finishes on small aircraft, using less time and money than competitive approaches.  Per your request, I have enclosed some sneakily taken photos of the fuselage which is covered with burgundy metallic.

The engine in question has been verified to be a 1/2 VW with an all up weight of about 88 pounds, developing 45HP (as I mentioned yesterday), with dual independent ignition.  This puts it at less weight than other four stroke offerings!  It is truly an aircraft engine on an ultralight aircraft.  My understanding is the Belite is pursuing this engine approach due to the fact that 1/2VW engines have been flying for 20 or 30 years, with good results, and that these engines are available fully assembled at reasonable prices.  In order to support them, Belite appears to have developed a custom four point isolated engine mount.  I also understand that similar 1/2VW engines may be built from 'scratch', from common plans ($25 or $30), utilizing off the shelf VW engine components.  Even better for Belite and their customers, the engines are available as kits at very reasonable prices.

Here are the spy photos I promised you:

1/2VW on Belite Ultralight Aircraft:  45HP of four stroke reliability

The above photo is a little better than yesterday's photo.  The exhaust pipes have been attached, and the magneto is reflected off the firewall in the rear of the engine.  The engine mount is clearly visible, as is Belite's custom developed heavy aluminum shock mount / engine mount plate.  BTW, I was able to see the alloy stamping on the firewall, and it was 7075 aluminum -- top quality aircraft grade.

Engine mount for 1/2VW on Belite Ultralight Airplane

1/2VW on Belite Ultralight airplane, from side

Tailfeathers:  Burgundy Metallic Vinyl over Dacron on Belite Ultralight Aircraft

Closeup of rudder cable exit plate (sharp white paint) on Belite Ultralight Airplane

Industrial Espionage continues at Belite Aircraft

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 #17

Mr. C.S.R.:

I was able to once again gain access to Belite's facility late this afternoon.  There were no employees in the facility, and I fear that I will be discovered.

As they are almost ready to load two planes into trucks to head to AirVenture (OshKosh), it is now quite clear what they are intending to show.

1)  First and foremost, they are introducing an "UltraCub", which is easily the best looking single seat cub look-alike ever seen.  The pictures posted earlier are the 'proof in the pudding', and the rumor is that their yellow aircraft was sold a couple of days after I leaked those photos.

2)  They are also preparing to formerly offer a vinyl covering option for their aircraft which is easy to apply over stretched dacron, and is offered in around 80 different colors, including metallics!!!.  The aircraft I saw being prepped will be shown at Osh with an absolutely gorgeous metallic burgundy / black / white offset marking paint scheme.  It is my understanding that they have discovered a 'blend' of three different covering systems that make this a winner -- Stewart Systems and two other products that produce a truly amazing look.

3)  I clearly saw a 1/2VW engine mounted on the front of the one of their aircraft.  It had dual ignition, including a magneto, and developed 45HP.  It uses far less fuel than 2 stroke engines, and is very reliable, as it has been sold for many years.  It's also proven -- 1/2VW engines have been used on Kitfox Lite aircraft in the past (the KFL was the architectural predecessor of the Belite.)  Even more fascinating, they've managed to reduce weight so that a full featured, ultralight legal, UltraCub can be built with the 4 stroke engine.  This was a stunner, and I have one photo of that engine which I will share below.

4)  It is clear that they have improved their wing design to use high quality low cost baltic birch ribs with aluminum spars.  This, combined with some other tricks, allows them to offer the 4 stroke option on a legal part 103 airplane, without the expense of carbon fiber.  Even so, carbon fiber pricing will be reduced and offers even more capabilities.

I'm just skimming the surface of what I've seen.  I'm hoping they announce price, show specials, and more details next week.

Four Stroke Engine on front of Belite Ultralight Aircraft.  1200CC; 45HP.

How to make an ultralight look like a Piper Cub

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!


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.