Thursday, March 8, 2012

How to attach an engine to an ultralight airplane

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!


NOTE:  This post describes the process for mounting a Hirth F33 (28HP) engine to a Belite Ultralight aircraft.  We support several different types of engines, all are similar in mounting techniques.  Call us (or the engine vendor) if you need installation information for any other type of engine.

The F33 is the exact engine that was used on the MythBusters Duct Tape Plane episode, which aired in October of 2011.  :-)

It provides awesome performance in our base aircraft.  This is due to the many aerodynamic improvements we've made to this airplane and our lightweight construction.  It is easily possible to fly a Belite with less than 210 pounds all up weight, including the engine!!

Let's get on with our engine installation...


Section A.  Firewall Assembly

Cut the firewall to the pattern supplied in our blueprint data.  We recommend using either 0.032 or 0.040 aluminum.   (If you don’t have the blueprint PDF for the Firewall – email us!  We will send it to you.) 

Fabricate the firewall from the aluminum sheet using the blueprint PDF template sheet. Cut the template sheet to size with scissors and then use spray adhesive on the template sheet to temporarily attach it to the aluminum sheet. Cut the aluminum with metal snips. Mark the templates' top contour on the sheet metal with a felt tip pen, but cut the top contour a little long (1/2" or so) in case your cowling does not fit up exactly as ours did. Any extra material will get trimmed away during the cowling fit-up sequences to come.

Using a brake, bend the bottom lip to fit under the fuselage, and drill holes at the engine mount locations.

Deburr all edges.



Section B. Engine Mount Assembly
Figure 1 -- Completed F33 Engine Installation in Belite ultralight airplane.

Tuesday, March 6, 2012

A retractable Pitot Tube on an ultralight aircraft

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One really cool feature we've been shipping on our ultralight aircraft is a retractable Pitot tube.  The old fixed pitot tube was a royal pain, and tended to get bent everytime we shipped an airplane in our trailer.

Solution:  a retractable pitot tube.  Credit for this idea:  Gene comes through again.

Here's photos as to how we do it:

First of all, this is what it looks like when it's extended.  We've placed the pitot tube through the leading edge of the wing, which is also our front spar.  Although this photo shows a carbon fiber spar, it works equally well with aluminum spars.  Also note that the location of the pitot tube is very close to the wingtip, so there is very little stress on the spar at this point.  (I have to have a very good reason to drill through a spar.)

Retractable Pitot Tube in Ultralight Aircraft


Monday, March 5, 2012

Funeral Arrangements for Sheryl Riney

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Received from Northridge this morning:

Dear Northridge Friends,

Here is the information as we have it for Sheryl Riney’s service:

There will be a viewing with the family on Wednesday evening at Broadway Mortuary, 1147 S. Broadway. The time has not yet been set, but we will inform you as soon as we know.

The Memorial Service will be Thursday morning at 10:30 at Eastminster Prestyberian Church, 1958 N. Webb Road. Participants will include Steve Dickey from Eastminster, Michelle Henderson, Earnest Alexander, Jim Smith from Friends University, and Ben Staley.

The Graveside Service will follow the Memorial Service at Kensington Gardens, 11500 E. 21st Street. There will be a luncheon for the family here at Northridge following the graveside.

Please continue to lift Doug & Paul, Cecil & Verna, Kevin & Michelle and their children, as well as Cheryl’s family in your prayers during this difficult time and the times to come.

Saturday, March 3, 2012

Sheryl Riney passes from this world to heaven UPDATED

FUNERAL NEWS:  We have just received word that Sheryl's funeral is to be at 10:30 on Thursday at Eastminster Presbyterian Church in Wichita, KS.  Double check with other sources... 

Sheryl Riney was Presiding Clerk of Northridge Friends Church, where I am assistant Presiding Clerk.  She was 52 years old, and died unexpectedly earlier this Saturday afternoon.  She is a dear friend of my wife and I.

Here is a very old picture of Sheryl, from 1987 (?) found on Facebook.

Sheryl Riney

Katie Henderson posted this recent photo on her Facebook:

Katie Henderson and Sheryl Riney

Katie wrote the most moving words, describing her stunned feelings upon hearing of her Aunt's death -- and much more about Sheryl.  You can read it on Katie's Facebook -- it is a 'must read'.

The Church posted this notice:

Dearest Family of Northridge Friends,

It is with very deep grief that I explain to you that Sheryl Riney surrendered her eternal presence into the hands of the Lord early this afternoon. For several days she has been seeking medical treatment in dealing with symptoms of a blood clot, yet without a complete diagnosis. At this writing word is that a blood clot lodged in her lungs and caused a fatal heart attack. She passed from this life to the next at around 1:30 this afternoon. 

Please pause throughout this evening and pray earnestly for Doug and Paul, Cecil and Verna, Kevin and Michelle, their families, Sheryl’s mother and siblings. Sunday Service Schedule: The Sunday evening business meeting has been indefinitely postponed. Normal service times of 9:15 and 10:45 will be observed Sunday morning. Both will be abbreviated in time. Some general announcement, words of comfort and directed prayer will lead both services at 9:15 and at 10:45. Following there will be an open-ended time of un-programmed prayer and soft music. The 10:45 fellowship time will be moved to the sanctuary for a come-and-go time of quiet prayer and reflection. Adult Sunday School classes may individually choose their participation. 

This is a time for our church to gather at the foot of the cross of Christ. He came that we might have life, and live it to the fullest. Sheryl Riney lived it to the fullest for the years she was granted. The tragedy is that she could have enjoyed 40 more so easily. Pray for one another. 

Yours, Larry Kinser

Monday, February 20, 2012

Flaperon Build Manual Update

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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

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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

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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.


Monday, January 16, 2012

Mile High

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This morning, I'd had no hope for flying today.  I called the airport weather line, and it reported that the wind was gusting to 26mph.  In a crosswind, making takeoffs and landings insanely impossible.

Come along with me, I have a story to tell.

I had wanted to fly this plane today:

Yellow Ultralight Aircraft from Belite

So, I went about my work in the shop, and felt badly that I couldn't fly due to the crosswinds.

Afternoon crept around, and another phone call to Jabara weather showed a much more favorable wind:  crosswinds had reduced to 15mph.  Improvement, for sure, but still well above my limit of 7mph crosswind.

Another hour later, and the winds were down to to 8mph.  With the ability of our huge grass runway to angle into the wind, either on takeoff or landing, I was now safe to fly.

====

The gas tank was not full, but I didn't care.  I wasn't planning to fly for more than a few minutes.  I wanted to check out some engine mounts that I'd been experimenting with -- which type would produce the smoothest engine, in conjunction with the new, amazing propeller we'd been trying out?

Last week, I'd tried the new propeller/engine combination for the first time.  On another aircraft, it had produced some fairly eye opening takeoff and climb performance, as documented in this video:  (Click on the picture, and go for a ride!)

Belite Ultralight Aircraft takeoff video
(Click on the CAPTION, and the video will load and play....)

Today, I was trying the same propeller/engine combination on the yellow aircraft, along with some slightly different engine mounts.

====

I'm off the ground easily and quickly, and the altimeter has passed 3000 feet in the climb.   (Ground level is 1400, so I'm plus +1600 over the ground...)  I'm kind of amazed that I'm not cold.  I have just my winter leather coat on, a hat, and some good gloves.  Normally, for winter flying, I wear coveralls.  But not today.

====

And now the altimeter has reached 4000 feet above sea level.  The views are beginning to be a bit surreal:  Jabara airport is now a long ways below me to the west; I can see Hawker Beech field to the south, and Benton (Stearman Airport) is just 4 miles to the west.

====

Still climbing; the altimeter passes through 5000 feet.  I no longer am doing anything other than having a good time.  For some reason, the idea of climbing is just a lot of fun.

====

The views are very, very good.  I am able to take off my gloves, and retrieve my phone from my pocket, and take some pictures:

Hawker Beech field to the south (left of center in this photo)

Jabara airport to my right

Looking towards the southeast

I keep considering the feel of the engine.  It sounds strong.  I make a note of the squawks to be corrected before customer delivery of the airplane, later this week:

  a)  the control stick is a little right of center in straight flight -- adjust rod end bearing setting to fix
  b)  (maddening)  the EGT/CHT is inop -- must fix!!!
  c)  midrange roughness in engine -- adjust belt tension to ensure no slippage and adjust carburetor mixture
  d)  the floorboard is made from beautiful stained wood (hey, we've always done it that way) but I've decided to change this airplane (and all future airplanes) to aluminum, for safety sake.  The muffler is below the engine and ahead of the floorboard, so putting in a floorboard firewall seems like a good safety idea.  We have some 2024 clad aluminum for this application.
  e)  the brake cable on the left side is skewed.  It needs fixing.
  f)  the radio still does not have the antenna installed, and needs to be tested thereafter.

I think I'm forgetting one squawk, but I wrote them all down and gave them to Gene after the flight.  

====

While the ground winds were 6 knots when I took off, I can tell that the winds aloft at my altitude are very fierce, yet very smooth.  I am pointed into the wind, yet I am hovering in place over my home field.  My ground speed slows to literally 10 knots.  (With a slight bit of work, I could have moved backwards.)  (And this is really no big deal.  I've done this kind of thing before in other aircraft.  I remember hovering over a wheat field many years ago, in a Cessna Cardinal.)

====

The altimeter has reached 5,200 feet ASL.  Just about one mile above sea level.  While I'm nowhere near the maximum ceiling of the aircraft, I'm running out of time, gasoline, and warmth.

I've been higher in a Belite before, but this flight was a little better documented.

Do you remember my old blog post,  What Altitude Did James Reach...?  I certainly flew higher that day.

Panel of Belite Ultralight Airplane at 5200 ASL!

Time to go down.

One more picture of me ---

James in Belite Ultralight Aircraft, really really high off the ground...
Really time to go down.

I push the nose over, and the airspeed indicator shows 70 mph.  (Redline is 80mph.)  I put in a couple of notches of flaps, and it helps reduce the fairly significant elevator forces, as the plane does not want to go down.  Of course, I work in some power reductions.

====

And I land.  Back on the ground.  Gene comments on how I'd been a hovering spec in the sky.

====

I've been recording the flight on GPS Essentials, on my DroidX phone:


The proof is in the flight profile.  Climb to 5200 feet; ground speeds below 10mph (and nearly 100mph); turning into the wind and with the wind.  Climbing at a steady rate of about 180fpm. 

(looks like someone made a move in Words with Friends)

====

Thanks for sharing this flight with me.

James Wiebe, @jamespwiebe on twitter, please follow me
James is the EAA 2011 August Raspet recipient


Saturday, January 14, 2012

World Class Takeoff and Climb

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!


Our Belite ultralight aircraft is now demonstrating world class takeoff and climb performance.

This is our new aluminum airplane design.  The propeller / engine combination has been tweaked for optimum performance and smoothness.

We've got some great new video which proves it ---

You can see the video here.

(Thanks to friend Jim Loewen for providing the video.)

Make sure you are following James on twitter:  @jamespwiebe

-- James Wiebe, EAA 2011 August Raspet recipient

Monday, January 9, 2012

Gorgeous Skies; First Flight; Video

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!


Hey Everyone,

Please remember to follow me on Twitter.  @jamespwiebe  I'll be twittering from Sun N Fun and Oshkosh later this year.

-----

It was a gorgeous afternoon in Wichita, KS -- temperatures in the low 50's, calm winds, blue skies.

I was scheduled for a first flight in a new airplane.  I've done this a fair number of times, and it is always a process which is cautiously approached and ultimately thrilling.

This particular plane is equipped with a 45HP MZ-201 engine.  I ended up flying it with a couple different propellers (none of which was quite right) and I look forward to flying the plane the correct prop later this week.

But this flight was still pretty cool.  I attached a high definition portable camera to the wing, and took video of the flights.  You can see one of the videos here on Belite's YouTube channel.

Gene captured some great pics of the maiden flights -- and a couple of them are just spectacular.

The new owner is in California.  We look forward to shipping this plane in a few days.

You might enjoy reading the following details:

1)  The windshield still has the plastic film in place.  We pulled it away only on the left side of windshield, and held it in place with tape.  I couldn't see out the entire windshield.

2)  The fuselage frame is a welded version of our new aluminum framework.  The entire frame is constructed from aluminum.  The wings utilize carbon fiber spars (which you can't see in the picture.)

3)  The paint is just UV resistant primer from Stewart Systems.  We expect the customer to finish covering and painting the airplane, but it's up to him.

4)  The engine is a 45HP MZ-201 from Compact Radial Engines.

5)  First flight was just smooth and easy.

6)  You can see the camera (from GoPro) mounted under one of the wings. 

7)  This aircraft has the big 5x5 tires.  Note the white tire labels are still on.

Ultralight Aircraft from Belite, aluminum frame

Ultralight Airplane from Belite, aluminum frame

Ultralight Aircraft touching down

Ultralight Airplane from Belite pulls in

-- James Wiebe, EAA 2011 August Raspet recipient


Thursday, December 29, 2011

Top 12 Things you can see in test flight video of ultralight 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!


Here is what you'll see, in this YouTube video of Belite's ultralight airplane:

10.  I turn to the camera and smile a lot.

9.  I do mild wingovers.

8.  I do steep turns around a point.

7.  I enjoy the beautiful weather on December 29, 2011.

6.  I get to prove that flying is more fun than working.

5.  I make the owner of this airplane wonder why I haven't delivered it already.

4.  I do a really sweet full stall 3 point landing.  If you look very, very carefully, you can see the steel landing gear springs barely compress, but just for a moment.

3.  You can see what a poor video editor I am.  Actually, I didn't do any editing ... just loaded the video to YouTube.

2.  At the end, you can see Mike, Gene, and my nephew, Matt.

1.  You can see the plane climb from ground level to 800' AGL in a little over two miles of ground distance.

0.  You can see me dive the plane to over 80 mph (IAS)

-1.  You can see why I enjoy doing this.





Sunday, December 25, 2011

Streamlined Struts produce zippy performance!

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Merry Christmas!!

One quick post on one of our development items, along with a new Belite video on YouTube --

I'll skip the analysis and just talk about the results --

After installing streamlined lift strut fairings on an airplane, I believe that we reduced drag at cruise speed by about 18 pounds.   This increases cruising speed, with our smallest engine, by about 5 mph.  That is very significant when we are talking about cruising speeds in the 50's with just a 28HP engine.

I borrowed Eric's plane for the installation and test of the new lift struts.  The proof is in pictures and video.  It's just a couple of minutes long, please watch this video!

Remember, I weighed 210+ pounds and the performance was just awesome.  The plane was also configured with our new improved flaperons.

We've also upgraded to a new HD camera for our inflight videos.  Just got it a couple of weks ago.  I learned a lot about how to mount cameras on aircraft when I was working at Mythbusters on the Duct Tape Plane myth., and you'll see much more airborne ultralight HD video in 2012.

James Wiebe, EAA 2011 August Raspet award winner

Wednesday, December 21, 2011

More on "Hoerner Wingtips" in ultralight aircraft

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My previous post cited the work of Dr. Hoerner in the development of wingtips which produce smaller vortices, which consequently produces less drag, which consequently allows more speed (for a given thrust), and consequently a better rate of climb....

Clearly the Hoerner wingtips are a desirable thing.  While there are other ways to produce effective vortice reduction (for instance, vertical winglets or even flat plates), the Hoerner wingtip is more easily fabricated, and frankly, in my opinion, just looks darn sexy.

Soooo, it's worthwhile to spend a couple of minutes reviewing Dr. Hoerner's research, so we can guess what positive results these wingtips will give us.

Below is a basic illustration of a wingtip vortice, which I have copied from Dr. Hoerner's most excellent book, "Fluid Dynamic Drag".

Vortice at wingtip, from Fluid Dynamic Drag, by Hoerner
This illustration shows how high pressure air is spilling from the underside of the wing out of the wingtip, causing the vortice.  (The villain isn't the vortice, it is the fact that a vortice is created by the loss of high energy air from the bottom of the wing.  The evidence and creation of a vortice only proves the problem.)

Dr. Hoerner reviewed several different kinds of wingtip configurations, including square wings with sharp edges (which is exactly what our Belite ultralight airplane has), along with round rectangular edges, sharp rounded wings, sharp full wings, and more.  He also reviewed vortices and drag  reduction around wingtip fuel tanks (which are not in our current Belite innovation plans.)   With each kind of wingtip shape, he calculated and presented the effective span of the wing -- in other words, a longer wing is a better thing -- and if you get that length 'for free' (by using better wingtips), that is a really good thing.

The very worst wingtip is a rounded wingtip, with a round cross section.  The very best wingtips are ones which have a sharp cross section.

And interestingly, the square wingtip with a square edge is nearly as good as the very best wingtip, but not quite.  It is worthwhile to quote Dr. Hoerner on this topic:

"Theory predicts minimum induced drag for elliptical lift distribution across the span....   however, directly in one case... that a rectangular wing (with sharp lateral edges) does not have a higher drag due to lift than the elliptical wing."

Wow.  Score one for Belite, and the game of innovative improvement hasn't even started!

Back to Dr. Hoerner's writing:

"It is seen that the most effective plan forms are the rectangular, the moderately tapered ones and those which have a long trailing edge....   In other words, to make the span of the rolled-up vortex system, or the effective span of a wing of given basic shape, as wide as possible, it is favorable to keep the tip vortices apart from each other as far downstream as possible."

Now if I look back at his charts, I do see that sharp wingtips have an advantage over the square wingtip with square edges, and all of those have huge advantages over rounded  wingtips.

So the Hoerner wingtip is taking it to the next level.

Let's find some more interesting remarks from my new best friend, Dr. Hoerner.  He makes some comments about the most ideal wingtip shape, which I (and others) now call "Hoerner wingtips":

"In case of [Hoerner wingtips], which is the most favorable one concerning small drag due to lift as well as to minimum sectional drag, it appears that one additional effect is the bent-up shape.  Experimental data.... on a small-aspect-ratio wing, confirm that this feature is important.  Combination of [Hoerner wingtips] with a moderately tapered plan form is believed to be the most effective..."

So things get a bit 'guess-work-eee' from here.  But we think that we know the following:

 * sharp wingtips reduce the size of the vortice -- which is what the Hoerner wingtip is all about
 * the addition of the Hoerner wingtip spreads the trailing edge, adding span, and further separating the vortice
 * sharp wingtips have less drag at higher angles of attack, which is where ultralights spend more time at than higher speed airplanes

Hey, wait a minute.  I better provide some documentation for a couple of those points.  Here's another illustration from the book which helps:

Improvement shown with Hoerner wingtips -- with square wingtips not far behind!
The illustration shows, on the top right hand side of the curve, the slightly higher coefficient of lift achieved with the Hoerner wingtips.  Square (Belite) wings are close behind, with round wings falling off considerably.

Here's a final helpful illustration, showing the cross section of vortices with sharp vs round wingtips:

Decreased vortice size with Hoerner wingtips (a) vs round (b) or wingtip tanks (c)







Finally, some conclusions...



Q.  So what is all of this worth to a Belite ultralight aircraft?

A.  We believe the aerodynamic effective span will increase by a little over 2 feet.  However, we are cheating a bit, because the Hoerner wingtips will add about 20 inches of real span all by themselves.  The increase in effective wing area is 7+ square feet!  (with an original wing area of about 108 square feet).

Q.  What performance increases will result?

A.  Hopefully I'll see an improvement in climb rate, a reduction in stall speed, a reduction in takeoff roll, a reduction in landing roll (I'd like to beat my personal measured 100.5' landing record -- which I know I'll be able to do [because I've already done it in another Belite, before I even started talking about Hoerner wingtips   :-)  ])  and more...

Q.  What weight penalty do the wingtips entail?

A.  Substantially less than a 8 ounces per wing, vs. our existing square design.   Really!


Q.  What if they don't work quite that well?

A.  Then I'll get to figure out why, and I'll have the coolest looking ultralight airplane on the planet.

My thanks to Dr. Hoerner, and his wonderful book.  I believe my quotes and illustrations taken from his book fall under fair use doctrine.

I am also indebted to Mike, who is building this wonderful test airplane with Hoerner wingtips for me.

If you want an overview of what else I'm working on (and willing to talk about) you can read it here:

Upcoming 2012 Product Innovations at Belite Aircraft

-- James Wiebe, 2011 EAA August Raspet award recipient









Monday, December 19, 2011

Upcoming 2012 Product Innovations 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!


"Upcoming 2012 Product Innovations at Belite"

 an overview of what's coming...
 this post focuses on "Hoerner Wingtips"

One of the absolute joys of my pseudo-job is that I get to investigate, implement and test aerodynamic improvements to my Belite ultalight airplanes.  As a result, I have come up with a goal of decreasing drag on our aircraft so that our very smallest engine option will allow cruising flight at 62mph.  (And the larger engines will require throttle limitations in order to stay within Part 103 -- or registration as experimental aircraft.)

When all is implemented, this will provide important improvements to takeoff and landing performance, along with substantial improvements to climb rate, reduced stall speeds.

Because our aircraft is so similar to a conventional high wing aircraft, I have identified several opportunities for drag reduction which are already available on many 'commercial' certified aircraft.  These opportunities include:

a)  lift strut drag reduction via fairings  --  all airplanes should have this
b)  wingtip drag reduction via reduction of wingtip vortices
c)  increased Lift / Drag in wing airfoil via subtle improvements
d)  reduced drag due to improved cowling design
e)  And maybe there will be more.

(none of these future options have been made available, or even priced yet)

I've already implemented and test flown a Belite with lift strut fairings, and I will provide a full report soon.  Hint at the outcome:  It was awesome.

I'm also working on a changed cowling design -- it will take a few more months and I'll have that one ready for report.

I've been reading through a variety of aerospace engineering reports on wing airfoils.  I find that my engineering and math background are an excellent helper for me as I've learned more and more about airfoils.

As for wingtip vortices, lots of people already know that Dr. Hoerner tested many different types of wingtips, in order to select and document those which increased effective span and reduced drag by reducing or eliminating those nasty wingtip vortices.  I happen to have gotten my hands on a copy of a couple of his books (they were loaned to me by a friend at my Church) and they have been delicious reading for my ultralight aircraft aerodynamic engineering education.

So, here's some photos of a set of wings in construction progress, showing Hoerner wingtips being fabricated.  These will end up on a plane which is being built to exhibit at Sun N Fun in 2012.  No opportunity for improvement is being overlooked in this airplane.  The wings in question are carbon fiber spars, with aluminum ribs, and the Hoerner wingtips.  You may also notice that they are also being prepared for VFR night flight via the addition of wingtip lights.  (The airplane is being built with a heavy 4 stroke engine, and will be registered experimental, thus allowing night flight.  It will be also be flyable as a legal FAR Part 103 airplane, albeit with a different engine.).  (This particular set of wings is being built by builder Mike.  Mike is awesome.)

So here are the pictures:

Belite Ultralight Aircraft wing, under construction with Hoerner wingtip

Detail of Hoerner wingtip, showing nav light fairing

Front view of Hoerner wingtip, with much smooth work still to do


Quartering view of Hoerner wingtip


View of Hoerner wingtip, prior to adding foam to front cell


Trailing edge quartering view of Hoerner wingtip


View of Hoerner wingtip from outside rear



Friday, December 9, 2011

Belite's Turn Coordinator: "More sensitive and more stable..."

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!


From one of our customers, we received this unsolicited testimonial concerning our Turn Coordinator and VSI:

Kathy,
Attached are two snapshots of my instrument panel "upgrade". The close-up shows the turn coordinator and the VSI (with an aux power port for my AdventurePilot 700/Skyradar kneeboard.)

I'm most impressed with the turn coordinator. It's both more sensitive and more stable than the analog instruments.

I've also tried using just the turn coordinator, VSI and the existing airspeed indicator as a "needle-ball-air speed" substitute, and it works very well.

I've also used the combination to fly the traditional two minute turn and I'm quite impressed.

Regards,
Ted Jula, KTAN
N701TJ (Zenair CH-701, Rotax 912ULS)

Here's the photos he included of his installation:

Belite's Turn Coordinator and VSI used in experimental aircraft

Belite's Turn Coordinator and VSI used in experimental aircraft

Thanks, Ted, for your positive comments!  The Turn Coordinator is our best selling instrument, and you've helped explain why.

Our Turn Coordinator is priced at $200 SRP.  Compare our product's performance and price to any old fashioned electric unit!

You can buy it from our webstore, or from Aircraft Spruce, or from Wicks.

 -- James

Wednesday, December 7, 2011

Risk, Cannonballs and Mythbusters

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!


... 

Risk, Cannonballs and Mythbusters

Last week, I deliverered an airplane to a new owner.  The airplane had been specially modified to meet the requirements of a handicapped pilot.  We'd modified the control stick and reduced the door entry height.  We'd also installed doors, simply to provide a little comfort on chilly fall and winter flying days.

James Wiebe flies a very special ultralight airplane from Belite; modified for a handicapped pilot

The aircraft had a number of features to increase safety:  aluminum fuel tank, extra wing spar, spring landing gear.  Even the cloth fairings on the landing gear arms cut dag, resulting in increased cruise and climb peformance.

Risk can be measured in many ways.  Flying our aircraft entails risk:  they are not certified; we sell them under the FAR Part 103 exemption which allows all kinds of privileges, in return for risk:  no medical, no pilot license, no aircraft registration.

Earlier today, I flew another ultralight aircraft:

Test Flight of a Belite Ultralight Aircraft (on the ground, actually)
 And I took some risk.  I am interested in providing a high quality product for my customers, so I realize that I must be willing to accept risk.  The engine was running roughly at high power:  a carburetor problem of some sort.  Gene and I fiddled with it, and I had it running acceptably for my test flight purpose, but certainly not acceptable for customer delivery next week.

In one or two days, I will test fly the same plane with a different propeller.  We will evaluate the performance of the propeller, because it is important to add to the body of information available to us, and to our customers as to what works best, and to our vendors, and to the greater community of aviators.

There is a financial reward, if I manage these risks appropriately.  Hopefully, this small business will continue to grow, and will eventually pay me something.  (The financial account has mostly run the wrong way.  Thankfully, that pendulum also is moving in a more positive direction.)  I've risked *a lot* on Belite. 

And now, Mythbusters.

Errantly, they shot a cannonball through the front and back of a house, off the roof of another house, and into a minivan.  They certainly didn't mean to, and before it happened, a lot of very intelligent people thought they had properly mitigated their risks.

Which goes to show, even the smartest of folks can't anticipate everything.  Risk doesn't always pay off (at least for the current account.)

I've read through many articles, I've researched the Mythbuster cannon shot literally from a bird's eye view (thanks to Google Maps), and I've seen what I believe to be factually incorrect (but irrelevant) reporting on their accident.  I read the twitter posts of Grant, Tory and Kari -- they seem to be taking responsibility straight on.  And from my limited experiences working directly with these people, I am confident they will make it right.  They are very proactive, they will rise above this accident, and they will be better for it.

Back to airplanes.

I want to help aviators fly.  This experience doesn't happen: ....

Belite Tricycle Gear Ultralight Aircraft landing
... unless I stick my neck out, invest the money, and fly the plane.  And let my customer do the same.

Risk can produce some beautiful things.

I can't help but think of our aircraft handicapped customers.  We have a couple of them.  Their ability to fly was severely eliminated by the FAA, but then they discovered Part 103 -- and our aircraft.  One of them (Eric) has become a wonderful friend of Belite, and has given Harley a beloved permanent home in our hangar.  He is allowed to risk and fly under Part 103, even though medical certificates would be denied, and Eric has received immense joy as a result.

For further background on why I say these things, consider reading Matthew 25, verses 14 through 28.  It speaks critically of people who don't take risks, and it speaks well of those who do.

Ultralight Aircraft from Belite touching down


Thursday, December 1, 2011

Beautiful Cub Yellow Ultralight 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!


Belite Ultralight Aircraft, aluminum construction, 45HP motor
I flew this plane today.  Loved it!  Phenomenal performer.  The airplane is constructed from aluminum, and is available with a variety of motor options.  Shown is a 45HP motor from Compact Radial Engines.  This looks very similar to the Duct Tape Plane which was featured on Mythbusters - same color, same taildragger configuration, but with aluminum construction and a bigger engine.  This particular ultralight airplane is soon heading to a customer in Missouri.

Belite Ultralight Aircraft, aluminum construction

Belite Ultralight Aircraft, aluminum construction