Friday, June 22, 2012

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.


Wednesday, June 20, 2012

Industrial Espionage at Belite

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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

Tuesday, June 19, 2012

Sneak Peek of upcoming Belite aircraft

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Yeah, I haven't posted much in the last 30 days.  Unlike a lot of blog authors, who blather on with apologies, make a weak post, then disappear from view, never to be heard from again -- I would rather say I've been busy.  And working on a number of very special things.  And I want to start sharing them with you.

Earlier today, I had a meeting with my wife and business partner, Kathy.  I opined that we needed to start the publicity engine for Airventure, and that perhaps it would be helpful to start 'leaking' information on our upcoming aircraft and product announcements into the market and customer base.  As no one drives by our workshop and takes spy photos (at least that I'm aware of), I have to be the one to let the information out.  Very carefully, of course, so no one will suspect that I am the source of the information.  So, this post is my first unofficial information leak.

Here is a photo of a work in progress:  our 'UltraCub'.  (That name selection is not final.)  You do have to use some imagination to fill in the rear turtledeck with fabric and paint, and you have to imagine where the windows are (in the half moon shapes.)

Belite UltraCub ultralight airplane, work in progress

It looks like it is going to be the perfect one man Cub.  We'll have one at Oshkosh.  More details then, including pricing and performance, and how it relates to the rest of our product line.

Notice the use of wood, which allows us to maintain low assembly costs and also easy three dimensional shapes.  Our use of our ShopBot helps as well -- the upper turtledeck is constructed from CNC milled Baltic Birch formers, and all of the longerons are cut from amazing aircraft quality fir.

Some more photos of the construction:

Belite UltraCub?  Ultralight Airplane, work in progress

Detail of UltraCub assembly, lots of clamps...

The lines on this plane are drop dead gorgeous.  The main color is cub yellow, of course, but we're thinking of doing the back upper fuselage in some shade of black.  Stay tuned.

There's lots more coming.

Saturday, June 16, 2012

Is the Wichita Lineman Back On The Line??

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Just before Father's Day 2012, James was camping in the Great Smoky Mountain National Park.  Skunked on flyfishing, he landed some very nice pictures of flowers, a bear, a deer, and Cades Cove, all in GSMNP.

Bear in Cades Cove, Great Smoky Mountain National Park

About 20 exceptional photos have been uploaded to Belite's Flickr account.  You can see them here.

Flower in GSMNP


Tuesday, May 15, 2012

Joy Of Flight - $10 / hour in 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!


Confession of flight:  I fly ultralights. 

I have a video at the end of this brief post which shows a flying experience from earlier this week.  You need to watch this video, but first, you need to hear how strongly I feel about ultralight aircraft and the experience of creating and flying them.

Belite Ultralight Aircraft

When I am in my ultralight airplane, I climb rapidly to high altitudes.  This is just the same as 'real airplanes'.  In fact, it is better, because I have a better point of view. 

I burn less than 2.5 gallons per hour, and I use auto gas.  My operational cost is about $10 per hour for flight.

I do not apologize for my aircraft's performance, because it leaves the ground as fast as many certified aircraft.  In fact, it is better than many certified aircraft.

I repair my own airplane.  When I see something that needs attention, I fix it.  I do not take it to a mechanic, because I have educated myself on just about every component in my airplane.

I practice takeoffs and landings, because I want to be able to land in short places.  And I do.  I've landed in 100 and 1/2 feet  (100.5 feet).  Someday, I'll do better than that.  But I didn't have enough practice a year ago when I did that.

I cruise at 58 mph.  This is more than fast enough for everything I do.  In fact, it is too fast and I will throttle back to about 50 mph.  I achieve this on 28HP.  My airplane is well streamlined, and I am still working on ways to make it fly more efficiently.

I can fit my airplane in small garages, because my wings fold in 2 minutes.  Really, they do.

My airplane was an award winner at Sun N Fun.  A variety of our planes have won a major award every one of the last 3 years.

I'm constantly innovating.  I keep finding ways to improve the experience of ultralight flight.  I share these with others who have similar interests.  I share them with my customers, and I share them with my aircraft.

I use my airplane to help others fly.  So far, I've helped two people with significant physical disabilities.  I hope to help more.

The Federal Aviation Administration does not view my airplane as a real airplane.  This is helpful, because it means I do not need a pilots license.  I just need to know how to fly.  I also do not need a medical, and I also am not allowed to register my airplane.  I have no desire to register my airplane.

I have practiced many things in my airplane.  I know what to do if the wing stalls.  (Push the stick forward, duh).  I know what to do if the engine quits.  (Keep the airplane flying, aim for a landing spot, try to solve the engine problem, if time permits.  If all else fails, pull the parachute handle.)

I taught myself how to fly a taildragger in my airplane.  I am now a very good taildragger pilot.  I enjoy taildraggers more than tricycle gear airplanes, and I never thought I'd be able to say that, or understand it.  But I do.

I have surrounded myself with good airplane people, who have like minds.  I receive great expert advice from Doug, the friendly A&P in the next hangar, who also builds components for helicopters.  I receive advice from  Neal and to his son, both of whom are aeronautical engineers.  My customers give me feedback.  On the business side, my wife is wonderful and balances my dreaming with great financial management.  She helps cover airplanes with dacron, too.

I want you to watch a video that I made yesterday, from the cockpit of a Belite Ultralight.  It's raw and it is jerky, and I spend a lot of time focusing on the instruments, yet it shows the joy of simply circling above fields.  I hope you find it enjoyable, and I hope it helps you dream.  Please enjoy the video.

Here it is.




Rear Fuselage Final Assembly

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Rear Fuselage Final Assembly
By James Wiebe, Belite Aircraft

After the rear aluminum fuselage has been attached to the aluminum cabin, several important details remain.  They include:

a)  Vertical Stabilizer Attachment
b)  Horizontal Stabilizer Attachment
c)  Elevator push pull tube Attachment
d)  Gas Tank Compartment Assembly

Each is fairly easy to do.  Let's get to work.

VERTICAL STABILIZER ATTACHMENT

The vertical stabilizer slips into the rear tube on the fuselage:

Vertical Stabilizer slipped into the fuselage
Note that the the vertical stabilizer is not parallel to the fuselage; although not shown on the blueprints, this is by design.  The front clearance should be about 2 1/2 to 2 3/4".

A hole is then drilled for a pin.  We use a AN3 pin (3/16" diameter) to slip the drilled home.

Hole drilled for AN3 pin.
The AN3 pin is then secured by a lock pin.  Since we did not have a pin of the correct length, we cut the AN3 bolt to the correct length (after insertion) and drilled it for a lock pin.

The front of the vertical stabilizer is attached to the fuselage using a couple lengths of 1" square aluminum tubing.

1" square tubes clamped in place

1" square tubes clamped in place
The 1" square tubes are riveted in place to the aluminum frame..  After riveting, the steel strap is drilled with a 3/16" hole and then the parts are secured with AN3 bolts, washers, and locknuts.  Do not use crushing torque on the locknuts.

AN3 bolts and nuts in place on vertical stabilizer

HORIZONTAL STABILIZER ATTACHMENT

The horizontal stabilizer is attached to the steel straps.  The critical factor is the angle of incidence of the rear elevator; to determine this, first level the fuselage (using levels at the cabin) then make sure that you set the horizontal stabilizer at an angle of 3 degrees negative incidence.  This means that the leading edge is lower than the trailing edge.  If you are assembling a taildragger, this means that the rear of the fuselage will be off the ground by around 15 or 20 inches, so that the airplane is level as measured at the cabin.  The airplane must also be leveled if you are assembling a tricycle gear airplane.   This normally requires shimming the nose wheel up slightly.

Horizontal Stabilizer in place, front bolt position determined by angle of incidence.  Elevator also is attached and drooping.

Horizontal Stabilizer, front and rear bolt shown.

The attachment of the flying wires is covered elsewhere in this manual.  A bottom cross connector flying wire plate is made from two pieces of aluminum,

 (PHOTO TO BE SUPPLIED of BOTTOM CROSS CONNECTOR FLYING WIRE PLATE), 

and is attached with AN3 bolt to the bottom aluminum plate.

Here's one more photo of the horizontal stabilizer, with the rear bolt attached.  Also note that the elevator has been test fitted using AN3 clevis pins.

Rear Elevator Bolt Detail.  Length of strap may be adjusted to set correct angle of incidence.   Elevator also attached.

ELEVATOR PUSH PULL TUBE ATTACHMENT

The rear elevator push pull tube is either 0.750 of 0.875 inches in diameter, and is constructed of aluminum.  It is rough cut to length, so that a neutral stick, and a neutral reversing bellcrank, and the elevator position is neutral, all at the same time.  Here are pictures demonstrating all of these requirements:

Neutral stick position

Neutral reverser bellcrank with elevator push pull tube attached

Neutral Elevator, looking forward through fuselage
The push pull tube contains a machined and threaded insert at each end, which is held in place with 3M 2216 adhesive, and a single AN3 bolt, drilled through the insert.  When it is cut to the proper length, everything is neutral, as shown in the above photos.

A diagonal member is placed and riveted on the internal fuselage frame, with a nylon or poly plastic block clamped in place.  The proper diameter of the hole through the bearing block is 0.125" greater than the diameter of the push pull tube.  For instance, for a 0.75" push pull tube, drill a 7/8" hole.  After positioning for perfectly frictionless movement, the block is then held in place with a couple of AN3 bolts, washers, and locknuts.

Diagonal with bearing block

GAS TANK COMPARTMENT ASSEMBLY

In order to construct the base of the gas tank compartment, a length of 7/8" by 1/2" angle aluminum is riveted to the rear of the fuselage cabin.  Then 3 cross members are riveted in place, followed by attachment of a aluminum sheet bottom.  Note that this compartment clears the top of the elevator push pull tube by about 1/2".  If it does not, the base level is too low and must be raised.

Angle aluminum across rear base of cabin and 3 cross members

Clearance from elevator push pull tube below gas tank compartment

Aluminum skin placed in position

Aluminum skin riveted in place



Wednesday, May 9, 2012

Evening Dream with Ten Beginnings

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!


Barn, from the air in a Belite Ultralight Airplane


I've mulled about 15 different ways to write about what happened tonight.  None are quite working, none express the sum of it. 

Try these beginnings, even though they are inadequate:

A)  I floated 400 feet over the trees and grass, all absolutely vivid green after one of the warmest and wettest spring seasons which the state of Kansas has ever seen.  Every pond had a dead flat surface; the deer snuck through a field already lush, and nearly ready for harvest...

Dead flat calm on a Kansas pond

or,

B)  Stress decompression therapy involved engaging in a kind of waking dream therapy.  For it to be successful, I assigned myself the task of observing stillness, green, fields and homes.

Homes in the Kansas Countryside, taken from Belite Ultralight Airplane
then again, what about this one?:

C)  A strip of grass, when long enough, and flat enough, provides a place to stop, and stretch, and realize that you've arrived at a place that could not have been reached and explored.  OK, maybe that's pushing it, but some runways are like that.

Grassy runway, in hayfield

Let's twist that last one just a bit:

D)  A strip of grass of a few hundred feet in length offered me a uniqueness not experienced by anyone else this evening:  literally dropping out of the sky, walking in the grass, taking pictures, then rising again from that strip.

Grassy runway, somewhere near Augusta, KS

Belite Aircraft pauses on grassy runway (WoW Plane)

Departing from grassy runway in hayfield

Yeah, that's Terry's runway.  Sort of.  Sorry I missed you:  I tried to call first.

So I don't know how to write an introduction to my Evening Dream.  Let's try another approach

Here's a fact based approach:

E)  After flying for about 1.2 hours, I still had half a tank of gas left.  This means I had been able to loiter in the sky for the evening on Two and One Half gallons of gas.  My direct operating costs were about $10 an hour, using $4 / gallon gas as my cost basis.  It also meant that I could plan a cross country FLIGHT of nearly two hours duration, and still have a little reserve.  Emporia is now in my grasp! ....

I'm not sure what picture follows that introduction.  Let's try these, even though they have nothing to do with burning 2.3 gallons per hour:

Kansas trees and bog from Belite ultralight airplane

Scrubby ground, trees, and field, all in Kansas

Kansas Countryside, from Belite Ultralight airplane

Kansas beauty, from Belite ultralight airplane
Another introduction might focus on landing at Stearman field, with its fairly amazing fly in restaurant, then taxiing by the restaurant and getting the outdoor patrons to smile, wave and give 'thumbs up' to the airplane which had just deftly landed on their runway.  So let's try that, as an introduction to this piece:

F)  I had no radio, so I was very careful to look in every direction for traffic.  I spotted a Stearman biplane landing at the airstrip, then saw a classic taildragger advancing around the pattern.  Crossing midfield, I snuck into the pattern behind the taildragger, then landed in front of the field restaurant.  Reversing course on the taxiway, the patrons nearly applauded as I taxiied by in my polka dot WoW plane.

This picture would go well with that story, so I'll let you look at it:

At Stearman Field, Benton, KS; while taxiing my Belite WoW Ultralight Airplane
((( DOES YOUR PLANE GET THAT KIND OF REACTION ??? )))  (Sorry for yelling.)

I went around the pattern at Stearman field, And I did a couple of landings there.

Here's a starting story approach which might appeal to someone who wants to know what stability this Belite airplane has:

G)  I was irritated with the fact that I still hadn't set the elevator trim just right.  I needed to keep some forward pressure on the stick, to keep the nose down and level.  Otherwise, it just wanted to climb.  Or so I thought!!  Out of irritation, I let go of the stick while I played with my camera.  To my surprise, the plane did something I should have known it would do:  It started to climb, then eased over into a dive, then started to climb again.  After four or so oscillations, it had entered a stable flight mode, slightly nose high, lower airspeed, but mushing itself through the sky in a state of equilibrium.  Having released the stick, I found that I could guide the plane entirely with the use of rudder pedals only. Occasionally, I shoved a bit of aileron to keep it level.  Dynamic pitch stability -- demonstrated.  Should have done that a long time ago.  Never had done it.  Now I could write about.  And speaking of technical matters, I did a two way speed pass, using my GPS to calculate average speed.  The average was about 58mph in cruise, which is a new record for our little 28HP engine.  (My goal is to hit 63 mph with just 28HP.  I'm closing in on it, as I've made steady technical advancements on Belite aerodynamics.)

That's too technical.  How about a sales pitch approach?

H)  We currently have assembled planes on sale for $14,500.  You can experience an evening dream like I did, but you have to be willing to part with $14,500.  In return, you can write your own stories.

That just is a horrible approach.  Sales pitches turn people off.

Or perhaps I could talk about the odd things spotted from the air, such as the car, or the boat, floating in a field of grass:

I)  I've spotted a fair bit of odd stuff on the ground.  There is *Nothing* like a small airplane, flown a few hundred feet in the sky, to spot the odd bit of man's impact on earth.  Today's examples include the abandoned car and a boat, still floating in a sea of grass.  I took a very nice photo of the boat.  And some other photos, too.

The boat sails on.
Windmill, Pond, Dusk approaches; taken from Belite Ultralight Aircraft

Perhaps a nice quotation from a famous person would set the right mood to start this tale:

J)   Quoting Peter Garrison: "No bird ever flew nonstop from New York to Tokyo, or raced 15 miles high at triple the speed of sound. But birds do something else. They do not conquer the air; they romance it."  And tonight, I romanced the air.  I found the beauty of a breathless evening; of breathtaking green; of softness; of gentleness, as not a puff of wind swayed my plane even as it hung on wind; of lightness, both in sky, in sunset, and in the touch of the earth on the plane as it floated down and touched the ground. 

---

That was potential beginnings of A) thru J), which is ten different beginnings to this tale.

I don't know which way is the best way to start this article, but I do know how to end it.

Thanks for sharing my evening dream.

Terry, I'm sorry you weren't home.  I would really have enjoyed seeing you.  Thanks for stopping by my field earlier in the day; sorry I missed you there as well.  The joy of all of this is experienced by sharing it with friends. 

A last photo:

Evening dream, taken from Belite Ultralight Aircraft

Okay, just one more photo:

Trees protect the creek and crook the field

Good night.  Sleep well.  Dream.