4 Stroke Opposed Engine on Ultralight - Confirmed Sighting

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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

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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

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How to make an ultralight look like a Piper Cub!

Well, the answer to that question is to start with a Belite and put an UltraCub Turtledeck on it.  The kit costs $500.  It includes all of the precut formers, along longerons and lightweight dacron fabric.  All the formers are CNC cut Baltic Birch plywood or aircraft quality Douglas Fir (in either 1/4" x 3/4" size or 1/4" x 1/2").  All you have to do is cut the wood strips to the right length and use good glue and lots of clamps.

The building surface is the back of your Belite.  This guarantees that whatever slight warps you built into your fuselage will be reflected in the turtledeck, guaranteeing a good fit and a good look.

In the following photos, we're using our super secret upcoming four stroke demonstrator airplane as the basis  of this particular turtledeck and resultant ultracub.

The photos are very self explanatory, so I'll keep comments to a minimum between the photos.  We'll start with a photo of the completed turtledeck, so you can see what you are trying to make:

Completed Turtledeck for a Belite Ultralight airplane -- UltraCub

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

Start by fitting the "A" former, the window formers, and the "B" former together.  You'll need to cut off the bottom of the "A" former, unless you want to leave the turtledeck permanently attached to your plane.  Cutting it off allows the former to be placed over the flaperon cables.  Also check the fit of the tabs.  They are a very tight fit and will need some help with your file or X-Acto razor saw to achieve a perfect fit.

Bottom of A former is cut off as shown

Gluing the A and B formers along with the window former

Gluing the window eaves former

Window eaves after clamps removed; bottom longerons (1/4" x 3/4") placed and glued

Gluing C, D, E formers to bottom longerons

Gluing F former in place to bottom longerons

Gluing top longerons in place -- two 1/4" x 1/2" and one 1/4" x 3/4"

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

Use lots of clamps.

Side longerons (1/4" x 3/4") and front angle gussett glued in place.

Top corner longerons (1/4" x 3/4") glued in place.  Longeron is fitted first to butt into corner.

Top corner longerons and lots of clamps -- a recurring theme.

1/4" x 3/4" stiffener glued to back of B former.  

Angle gussett glued to top longerons on each side

Square gussett glued in place on C former.

Additional (sideways) top corner longerons glued in place, forming 90 degree angle longerons

Between Former stiffeners cut, fitted and glued in place.

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

more stiffeners on the higher level.

short longerons cut, fitted, glued and clamped in place.

90 degree square gussett on E former

All longerons trimmed off, view from front.

quartering view of turtledeck for Belite ultralight aircraft -- UltraCub.

view of rear of turtledeck.

Your turtledeck is now ready to cover with Dacron fabric.  

more spy photos

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Ultracub from Belite

Ultracub from Belite:  ultralight airplane looks like J3 Cub

Ultracub from Belite

Tail Feathers on UltraCub

Ultracub from Belite:  Looks like Piper Cub

Ultralight Ultracub Aircraft from Belite

TOP SECRET -- EYES ONLY FOR UNDERSIGNED

Please note: James' blog has moved to a Wordpress site. To access it, please visit http://jameswiebe.wordpress.com/. All posts have been transferred to the new site, and all new posts will only be accessible via Wordpress. Thank you for your interest!


TOP SECRET -- EYES ONLY FOR UNDERSIGNED

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


Mr. C.S.R.:

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

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

Belite UltraCub?  Spy photo

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

Belite UltraCub, side view

Belite UltraCub, quartering rear view

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

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

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

Detail of Belite's UltraCub

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

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

James Wiebe (Belite President) holding UltraCub rear fairing

Mr. Wiebe discusses structure of UltraCub?

Mr. Wiebe with left hand thumb in bandage?!

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

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

Industrial Espionage at Belite

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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

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.

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

Joy Of Flight - $10 / hour in an ultralight airplane

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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.