aluminum fuselage update

Here's some photos showing some of the ways our fuselage design has mutated from 4130 steel.  I've also made some comments on strength.

The front of the fuselage is made from 6061T6 aluminum, and is welded.  The rear of the fuselage is made from 2024T3511 aluminum, and is riveted.

The hallmarks of this design is that it is very light, very strong, and easy to assemble.  Let's look at some pictures.  The first picture shows that the primary vertical members are 1.0" aluminum square tubing, with .063" walls.  Although the temper is 6061T6, the welding is assumed to reduce the strength.  This particular tubing doesn't have the heavy loads.  However, it is also a primary safety mechanism to enclose the pilot in the event of an accident, so we still want it to be strong.  Assuming 0 temper, the strength of this material is about 4,500 pounds per tube cross section.

1" square tubing used in Belite ultralight aircraft

 

 

The front section of the fuselage is where the engine mounts attach.  We've reinforced this section with 4" gussets.  Here is a gusset at the top of the front fuselage:

Gusset reinforcement

 And here is a gusset on the bottom of the front fuselage:

Gusset reinforcement is on bottom of fuselage

 

 

Now let's look at the front spar crossover.  It is constructed of aluminum tubing (about .080 wall) with reinforcements in both axis.  As a result, it has a critical length of about 12 times its diameter, which means that the effects of "Euler's Buckling" have been reduced or eliminated.  At normal loading, this spar crossover has about 650 pounds of force pushing through it.  At a 4G load, it would have around 2600 pounds of force.  Assuming 6061T0 temper (welded), the cross section strength of this material is about 4000 pounds.

Front Spar Crossover with reinforcements.

Now let's take a look at the rear spar crossover.  We've reinforced it with some 1" square material.  The failure strength is substantially stronger than the front spar.

Rear spar crossover with reinforcement

 

 

 

Here's another view of the rear spar crossover:

The above photo shows the bracing.  The braces help prevent the cockpit from torsionally twisting.

rear spar crossover with bracing shown

The pilot's seat also gets some strengthing:

0.5 x 1.0 aluminum tubing added to pilots seat

Tricycle gear versions of our planes get extra cross channels on the bottom, along with more bracing in the side cabin area:

Tricycle gear airplanes get even more cross channels

 

And now let's show how the rear fuselage is added on.  We start with four longerons built from 2024 aluminum, with an angle size of 0.875 x 0.5 x 0.063 inches.  We then add some bulkheads, a vertical stabilizer, and some rivets.  We also use gusset plates.  Since there is no welding in the rear of the fuselage, the 2024 is an excellent choice.  (You can't weld it, but good golly goodness is it strong.)  Tensile strength of the longerons is off the charts:  each longeron could lift nearly 5900 pounds.  In a few more days, I'll have some photos of the completed rear fuselage.

Rear fuselage of Belite's aluminum airplane

rear view of the rear fuselage of Belite's ultralight aircraft

front view of the fuselage, it's all coming together

Broken Flaperon Repair

We just repaired our proto aluminum airplane.  We put triplers on the root flaperon riser, and we put a doubler on the opposite end flaperon riser.  We did this on both flaperons, left and right.

The doublers were reinforced with JB Weld (cleaned and roughed surfaces first) and the extra new pin bolt is a stainless 6-32 bolt with a locknut.

In the second photo, you can faintly see the crack on the original flaperon riser.

Here's the pics:

The original failed part is in the middle of the aluminum sandwich, above.

6-32 stainless bolt with washer.

Right wing riser with reinforcements.  This one wasn't cracked.

Outboard flaperon riser with doubler.  We reinforced both outboard left and right flaperon risers.

Inboard flaperon riser with triplers, JB Weld, and bolt (which will be trimmed).

Service Bulletin: Broken Flaperon Riser

As Belite manufactures Part 103 aircraft, and also parts for experimental (customer-built) aircraft, this bulletin has no force of law.  You may choose to follow our advice, or ignore it.  We hope you follow our advice. A picture of the broken part, along with a new part is at the bottom of this post.

While inspecting our prototype aluminum airplane, one of our personnel found a broken aluminum flaperon riser on the innermost position on the flaperon.  (The position closest to the fuselage, or root of the wing, where the flaperon connects to the control cable).  Further examination determined that this was a fatigue failure.  This failure appears to have been possible where ever this part was used, and we have been using this part for some time in our entire line of aircraft.  We do not know when this failure occurred.

We have sold aircraft and kit parts with these flaperon risers.  Some were made of steel, some were made of aluminum.  We do not know which customers have steel or aluminum.

If your part is made of steel, you may ignore this directive.  We believe the steel parts are OK.

If your part is made of aluminum, we recommend that you immediately install a reinforcement before further flight.  We are in the process of designing an improved part, and also designing a reinforcement plate for existing installations.  We expect this redesign to be completed by the end of next week.  We expect replacement parts and reinforcements to be available sometime soon thereafter.

Please contact us if you believe you have affected parts, so we can advise you when reinforcement straps are available.

In the future, we will be creating a place for service bulletins on our main website.

The photo is below:

Fatigue Failure on Flaperon Riser

Fear and Loathing in Northrock Business Park

It was close to lunch time, and I opened the door to my office ---

And saw a collection of people down the hallway, just outside of Senator Jerry Moran's office.  (The Senator and I are office neighbors.  One thin wall separates his staff personnel from my office/lab.

What?!

I heard passionate words; a variety of voices, and I noticed the head staffer standing in the hallway, listening patiently to a mixture of anger, confusion, persuasion, and distrust. 

45 minutes later, they were gone. 

It's early in the campaign season; I'm sure there will be more.

Random Observations:

1.  Why am I next to a Senator's office?  (A:  It's actually a great place to be.)

2.  Who was this group?  (A:  I'm pretty sure it was moveon.org)

3.  What does this have to with ultralight airplanes?  (A:  not much.)

4.  What does this have to do with "Fear and Loathing" (Hunter S. Thompson's famous novels/movie)? 
(A: Well, I was handed a button which said, simply, "Dream".  In some sense, "Fear and Loathing (the novel) was about a pursuit of the American dream.  And then there's "Fear and Loathing on the Campaign Trail", also by Thompson.  Seemed like some convenient parallels.)

Fascination of flying like a bird

I've never just posted a link before.

But today, I make an exception.

Here is a video of a model airplane which flies *exactly* like a real bird.

Best Aircraft at Oshksoh 2011

Long time readers are aware of my interest and experimentation in electric aircraft.  Here's the first one I've seen that appeals to me.  It had reasonable performance, length of flight, and simplicity.

My attempts to fly the Belite with electrics have produced a very good, very short flight.  I'd shelved the project until I had some inspiration worth working on.

I learned a lot from this plane.  Got my inspiration back.

Photo Essay on Balloons at Oshkosh 2011

(c) 2011 James Wiebe, Reproduction prohibited without written permission.

My co-worker Gene took the following photos at the balloon launch this morning.  They are stunningly beautiful.  Enjoy:

James Wiebe named "August Raspet" EAA award winner for 2011

Hi Friends,

I've got big news.

A few weeks ago I received a letter from Rod Hightower.  He is the president of the EAA -- and the EAA is the most important voice in experimental aviation in this country.

I was informed that I had been selected for this year's "August Raspet" award, which is given annually.  Quoting the EAA:

"Since 1960, the Dr. August Raspet Memorial Award has been presented every year to a person who has made an outstanding contribution to the advancement of light aircraft design."

They cited three reasons for awarding this to me:

1)  My work in developing carbon fiber in ultralight aircraft;
2)  My work in developing lightweight instrumentation for aircraft;
3)  And my work in developing "water in fuel" technology for aircraft.

I was mildly stunned by this news...

Anyway, this evening, they have posted the news story on their website:

http://www.airventure.org/news/2011/110727_raspet.html

And tomorrow night (Thursday) I receive the award.

Kind Regards,

James (For my latest news, I suggest you follow me on Twitter:  @jamespwiebe  @beliteaircraft )

New Ultralight Airplane promotionally priced for $14,500

Too much to report to you.!

It's Oshkosh week, and Belite has *lots* of news throughout the week.  We'll take our news one chunk at a time; let's start this post with our aluminum ultralight aircraft.

We posted a great video of our new aluminum airplane flying.  We have the prototype of this aircraft at Oshkosh this week, so please come by our booth and see it.

You can see the video of the aluminum ultralight aircraft here on youtube.  We demonstrated it with a 45HP engine, but we will be selling it with our 28HP engine (expect great performance) and also the 50HP twin Hirth (expect unmatched performance).

Prices on this airplane start at $16,500, Ready To Fly.  (Our Oshkosh special promotional price is $14,500, but YOU MUST place a completed order with deposit postmarked by the end of August.)

This aircraft incorporates a bigger wing and a better tail design (compared with older Belites).  Also, in base configuration, it is UK SSDR compliant!

This airplane, in kit form, sans engine/prop/instruments/fuel tank, is $6800.  

An Aluminum Dream

(There is news far below of a new aluminum version of our plane.  Read down...)

***

I've had a dream.  In it, I'm able to take a simple board, lay it across my chest, and in a few steps I am flying.  Somehow, I lay on the board, and it generates enough lift to take me above trees, mountains, streams, and beautiful things.

I do not understand how this can be.  I am not Jetman, but I know that it is real, and in my dream, I am gliding down over a descending landscape.

I am able to breeze by trees, houses, birds, and under a clear, blue sky, I am able to select a landing spot.  In my dream, I land just a few minutes after I take off.  Sometimes, I have a passenger nearby (I do not understand this either.)  But mostly, I am free, and I simply fly.

I feel the joy, and I am determined to share it with others.  I see that as a role given to me:  to spread the joy and the ability to fly above and observe above and be above.  To be above.  To fly.

***

Two days ago, I was down in Tulsa, Oklahoma, making some simple wiring fixes to a plane we'd delivered to a new Belite owner.  The airstrip was overkill long at 1320 feet; there were horses on either side, and the hangar was in the back yard of the house.  Ironically, a windsock was 3/4ths of the way down the strip, and it was positioned nearly in the middle of the runway.  I asked the owner if I could once again fly the plane that was formerly mine, and he said, of course, 'yes'. 

Once around the pattern, a low approach. 

Another time around the pattern.  A hot day.  But 300 feet above the ground, things were comfortable in the open cockpit.

A second time around with a lineup to final approach.  A good breeze out of the east.  A crossing landing on the runway, drifting from left side to right side, making advantage of the crosswind.

Landing.  Barely disturbed the grass blades -- a combination of luck, maybe some skill, some springy gear, and some big fat tires.

Out of the plane.  My wife took my picture, as did one of the new owners.  The other owner showed up late, I started the engine just so he could see it easily start.

***

He called me earlier today, and I answered.  I am in West Virginia, getting ready to deliver a series of talks on computer forensics at Marshall University.  He wanted to know how to adjust the tension on the throttle lever; and I gave him some quick advice.  He'd flown the bird, rechristened 'Queen Lady', and he was tiring of readjusting power continuously.  Surely, an understandable aggravation.  But he'd flown around for 30 minutes, and I was pleased for him.

***

Two planes sold in 24 hours -- that's news.  One heading to California, the other to Missouri.  We cut the prices on some of our planes in order to reduce inventory, and in order to prepare a way for a new aluminum variant.

***

I've always been in love with technology.  I enjoyed putting carbon fiber spars on ultralights -- I thought the strength / weight thing was simply amazing.  I ignored the economics -- figured people would pay.  A few did.  Not many.

***

Kathy and I put out a pricing survey on our planes.  It seems these are the most important things to many of our potential customers:

a)  They like our plane.
b)  They want to fly.
c)  They want to afford our plane.
d)  They may weigh a little too much -- but they still want to fly.  Do we have a plane that will accommodate them?

***

Belite has been in development of an aluminum fuselage of our plane.  An original prototoype was built, and we did a series of tests on it: 

a)  Engine mount strength
b)  Pilot seat strength
c)  Airframe strength -- taxiing  (super hard jolts while going up and down the runway without shocks).

Engine Mount Strength -- over 400 pounds of steel.  Ken needs to smile.

Pilot Seat test -- 819 pounds of steel and sand

Well, I broke the plane while doing initial taxi and flight test.

So we redesigned the cabin area, and a bunch of the round tubing was replaced with square tubing -- much stronger.  It ended up looking like this:

Closeup of square aluminum tubing

So here's a photo of an aluminum airplane.  Notice the heavy cockpit structure, also the monocoque aluminum skin on the sides, (carrying landing loads).  The landing gear is chromaloy steel, and the engine mount is also chromaloy steel.  The aerodynamics are largely undisturbed from our sweet flying, original 254.

Aluminum Fuselage Ultralight Airplane from Belite Aircraft

***

Pricing to be announced at Oshkosh on these models:

a)  Aluminum Belite 254 taildragger with 28HP engine.  Weighs about 210 pounds.  UK SSDR compatible as well!
b)  Aluminum Belite 254 Trike with 28HP engine.  Weighs about 220 pounds.  UK SSDR compatible as well!
c)  taildragger with 45HP engine.  Weighs less than 254 pounds.  Phenomenal takeoff performance.
d)  same thing in Trike.
e)  deluxe taildragger with 50HP engine, carbon fiber, 'chute, every option we make. 
f)   deluxe trike with 50HP engine.

And yes, we're still working in the 4 stroke engine.  And the aluminum kit version.

***

Many of our potential customers are concerned about their weight in relationship to our planes.  These new aluminum planes solve that problem. 

The 45HP engine, in combination with the lightweight aluminum fuselage, provides the ability to lift a lot of load!  We can now handle pilot loads up to 275 pounds in the taildragger configuration.  With really great performance!

***

The aluminum fuselage airplane pictured above has already been presold to a customer.

***

We have two more fuselages already started.  We will have at least one aluminum ultralight at Oshkosh.   Please come see us.

Belite Ultralight Aircraft @ Mythbusters

(c) all photos by James Wiebe, Reproduction prohibited without written permission

If you read all the way to the bottom, I'm posting some more great photos of working at Mythbusters, including some photos of the MythBuster gang and a Belite Ultralight Aircraft.  If fact, the airplane pictured far below is the same aircraft which won "Best Commercial Ultralight" at Sun N Fun -- refinished with a different engine and as a showstopping taildragger....  But first, some of the editorial on what it was like:

ARRIVING MYTHBUSTERS STUDIO, AKA 'M7'. 

No, I'm not shouting, I'm just in shock.

I'd been given the address to drive to by the Associate Producer, a very nice guy by the name of Eric Haven.  I really didn't know what to expect, other than the Google Map streetview had provided a grainy photo of an industrial area near the city's downtown.

I drove into the parking lot, and passed business unit after unit, waiting to find the one that said "MythBusters" on the door.  I realized that nothing said MB on the door, but that the contents of the parking lot had somehow shifted from average cars to a collection of strangeness:  a vehicle which looked like a small desert tank in progress; a bomb bunker, large markings on the parking lot (like a bomb drop "X"), and an oddly painted VW beetle.

I realized I had found Mythbusters.  Kewl.  In the door I went.

Which I did -- went in the door, expecting amazing offices and greatness, and I walked instead into a common room with desks crammed together, a huge mess on all of the walls, a small black dog, and people who were very busy.  And a Mythbuster host or two at their desks, working (or playing) right in the midst of the chaos.  And a big warehouse in the next room, where all the non-location shots would be setup and filmed.

Debris of a hundred episodes spread throughout all the walls, floors, ceilings, parking lots, desks, bathrooms, storage cabinets, and vehicles.

Hey, I can't tell you what we did.   I've signed a blood enabled non-disclosure oath.  But I can tell you some other things:

1)  Our myth will certainly use a Belite airplane.

2)  I've never been a part of a work environment that was so ad hoc on the back end.  What a riot!

3)  The hosts (Tory, Grant, Kari) are fun, witty both on and off camera.

4)  The hosts (Tory, Grant, Kari) can be serious, can show concern and compassion just like all good human beings.

5)  The hosts (Tory, Grant, Kari) really do everything you see them doing on the show.  And they do a lot more.  They are working the myths with great diligence.

6)  There are other people who are also working just as hard to make sure that the show is great TV.  I've mentioned Eric, but there's also John, Lauren, Benny, Amid, Duncan, and many more.

7)  Not that I've had great opportunity to, but I've never seen a group that knew so much about how to get a great camera shot.  Both first and second camera (Ben and Duncan) know their stuff forwards and backwards.

8)  MB very graciously allowed one of my daughters to join the fun for a day.  Duncan (2nd camera) even more graciously took her and put her to work, instructing her on building a super cool show prop (which she did) and having her directly assist with setup on a "Mythbusters" logo shot, which they do frequently and freshly for each episode.  I even got to contribute some thoughts to that particular logo shoot.  It took them 3 hours to produce less than 2 seconds of video.  The end result was world class super hi-def slow-mo footage shot on an amazing hi speed camera.

9)  For all of the fun on camera, there are people who are sweating details.  The producers and the director have plates full when the project is on -- there are loads of unforeseen things (EG:  no porta-potty on location -- where to Pee? -- find a porta-potty).  Some of the unforeseen things cause the director to think on their feet; some of them cause the producer to think on their feet; some of the problems cause the hosts to think on their feet.

10)  It's teamwork.  You have to work very hard to make great TV.

First Camerman and Sound

Duncan *WANTS* this airplane.

Some Mythbusters on the (closed) runway.  Notice there's nothing around:  miles from people.

Kari Byron, 'nuff said.

MythBusters, Lauren (Director) and Benny (1st Camera)

Tory dreams of takeoff in a Belite Ultralight Aircraft.  Sorry, you need some training first.

Tory, Grant, Kari, Jennifer and James with Belite Ultralight Aircraft

More Mythbusters!

Tory, Grant, Kari, James, Jennifer @ Mythbusters!

Tory, Kari, James, Jennifer, Grant @ Mythbusters

What an awesome amazing week.  And more to come...

At MythBusters!

I've been spending the week at Mythbusters, helping them produce an aviation themed episode for an upcoming show.  Here's some pics:

With Tory and Jennifer - I need to smile!

 

Duncan, 2nd Camerman, Mythbusters with Hi Speed

Jennifer helps with hi speed Camera!

Awesome Cameraman and Soundman at Mythbusters

Jennifer and Busted!

James is Confirmed!

I'd love to share more, but that's all for now.