Thursday, July 26, 2012

Too Sleepy For Anything Serious

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!


Just 6 pics.

4 Stroke Engine on Belite UltraCub Ultralight Aircraft

4 Stroke Engine on Belite UltraCub Ultralight Airplane

Belite UltraCub with Metallic Burgundy Paint

Engine and Landing Gear on Belite UltraCub

Helicopter over ultralight field at #Osh12

Helicopter over ultralight field at #Osh12

Monday, July 23, 2012

FAQ’s on Belite’s “UltraCub” and ½ VW Four Stroke engine


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!


FAQ’s on Belite’s “UltraCub” and ½ VW Four Stroke engine
The following information is subject to change without notice


1)                  Q:  What is a Belite UltraCub? 
A:  The Belite UltraCub is an ultralight airplane manufactured by Belite.  One configuration has the following major characteristics: 

a)  4 stroke engine
b)  Traildragger configuration
c)  Rear turtledeck which gives it the appearance of a Piper J3 Cub.
d)  Legal Ultralight under U.S. FAR Part 103

also,

e)      Users may build an UltraCub from a kit from Belite.  The single defining characteristic is the rear TurtleDeck option.

Belite UltraCub with 1/2VW engine
Finally,

f)  The TurtleDeck is available as a build option by Belite for any factory built airplane.

TurtleDeck on Belite UltraCub


2)         Q:   What standard features and benefits does it have?
            A:  They are:

a)      Standard basic instruments:  hour meter/tach, inclinometer, EGT/CHT, Oil pressure warning, Oil temp gauge, ASI.  All other instruments are optional.
b)      spring steel main landing gear, which are much better than bungees, softens landings and taxiing
c)      differential (independent) main gear disc brakes with heel pedals
d)     Single color ( with color selected by owner) Oracal (vinyl) finish over the entire airframe, fuselage, wings and tail feathers.  Very beautiful finishes!
e)      Rear steerable tailwheel with steel tail wheel spring.  In conjunction with brakes, gives easy ground manners.
f)       Aluminum fuselage – riveted construction utilizing mainly 2024T3 longerons; also 7075 and 6061T6 aluminum in critical areas.  Other alloys are also used.
g)      Lightweight 6061T6 aluminum lift struts.
h)      5” Azusa nylon aircraft wheels with 5” wheels
i)        4130 Chromaloy steel landing gear “A” frames
j)        Polycarbonate windshield and sunroof
k)      Easily and quickly foldable wings
l)        Enhanced wing area (40” x 144”)
m)    Enhanced flaperons (12” x 120”), reduces stall speed and improves roll control.
n)      Functional Winglets, increasing lift, reducing vortices, reducing drag, increasing flaperon effectiveness
o)      Intermixed aileron / flap controls, providing standard stick (aileron) and standard flap (flap handle) control with 3 notches of flaps.
p)      Multiple storage compartments under seat
q)      5 gallon plastic fuel tank.
r)       This aircraft does not include an engine cowl.
s)       A hand deployed emergency parachute is included.
t)       The engine has single electronic ignition. 

3)                  Q:  What does an UltraCub cost?
A:  $27,995 + $2.25/mile delivery charge (one way) to any US destination.  Other configurations are available for as little as $16,495.

4)         Q:  What does an UltraCub kit cost?
A:  $7995 (base Belite Kit cost) + $500 (turtledeck kit cost).  This doesn’t include main gear springs or brakes, but it does include solid gear links, and mechanical (drum) brakes are available for $100 extra.  It also doesn’t include a fuel tank, but we buy ours at Walmart for about $12, and you can too.

5)         Q:  What type of construction is used in the fuselage?
A:  It is straightforward aluminum construction.  Most of the gussets have pre-drilled pilot holes, and the rear fuselage is pre-aligned, mostly pre-drilled and ready for you to start riveting.  All main cabin bulkhead formers and gussets are CNC cut and have many pre-drilled pilot holes as well.  The builder has to cut cabin longerons and members, but as these lengths are short, and all formers are square, the resulting assembly process is easy and straightforward.  Aluminum may be cut with a carbide blade table saw, or a band saw, or a hack saw.

6)         Q:  What type of construction is used in the wings?
A:  The wings are built with aluminum spars and CNC cut Baltic Birch ribs.  Everything slips together and is locked in place with Gorilla glue.

Belite wing with aluminum spars, CNC cut  Baltic Birch
7)         Q:  What type of construction is used in the tail feathers?
A:  The purchaser may select between aerodynamic horizontal stabilizer/elevator or pre-welded stabilizer/elevator.  The pre-welded feathers simply need to be covered.  The aerodynamic feathers are easy to build and very straightforward, like a big model airplane wing.

8)         Q:  How is the structure covered?
A:  We use generic Dacron, glued and shrunk to the underlying wing or fuselage structure.  We use a special glue (Hipec) for attachment of fabric to the underside of the wing.  We use Stewart Systems glue for most other fabric work, and we use Oracal vinyl (available in about 80 colors) for covering over the shrunk fabric.  Kit builders may use whatever system they are comfortable with.

9)         Q:  What does an UltraCub weigh?
A:  As built by Belite, with a four stroke engine, and as described in this document, it weighs 278 pounds.  This is the maximum allowed by FAR Part 103.  (Our configuration includes a parachute which is deployed by hand, for which FAR Part 23 provides a 24 pound allowance.) The rear turtledeck is not included in this weighing, as it is removable for flight.  (The rear turtledeck weighs about 7 pounds).  Much lighter weights are possible by using two stroke engines.

10)       Q:  I see that your configuration doesn’t include an engine cowl.  How could I add one?
A:  It is available as an option for $350.  We don’t weigh them as they are removable for flight.

11)       Q:  What other options are available?
A:  Bigger Tires and Carbon Fiber main spars will be popular options.  The Carbon Fiber spars save 9 pounds, which would allow nice big 5.00 x 5 tires.  $2400 total.    Doors and trailering kits are also available.

12)       Q:  Are other instruments available?
A:  We are happy to install any instrument manufactured by Belite Electronics, including Turn Coordinators, fuel gauges, etc.  We do not install other instruments.  We recommend you have other installations (EG, radio) performed by your local instrument shop.

13)       Q:  Does the four stroke engine have electric start?
A:  No.  The 1/2VW are very easy to hand prop, and the electric start option is too heavy for our FAR Part 103 usage.  It would be a great option for aircraft built as ‘experimental’, though.

14)       Q:  What power does the 1/2VW four stroke engine develop?
A:  45HP. 

1/2 VW Engine
15)       Q:  Who is the engine vendor?
A:  Scott Casler, Hummel Engines.   www.hummelengines.com 

16)       Q:  Will other 1/2VW four stroke engines work?
A:  Absolutely.  We recommend at least 37HP.  Great Plains is a good source for plans or a complete kit – see:  http://www.greatplainsas.com/schalfvw.html  And as of this writing, their 1/2VW kit is under $3400. 

An online build manual for 1/2VW engines may be found here: 

17)       Q:  What about the motor mount for a Belite and a half V/W?
A:  We designed it, and it is pretty sweet.  It includes a Chromalloy steel mount and aluminum mount plate.  $300.

Engine Mount for 1/2VW on Belite Ultralight Airplane
18)       Q:  What kind of fuel consumption does the engine have?
A:  We expect fuel economy to be about 2 GPH in cruise.  This number will be verified in August.

19)       Q:  What kind of gasoline does the engine use?
A:  91 Octane automotive.  100LL will work, but be aware of lead fouling issues.

Friday, July 20, 2012

Burgundy Metallic UltraCub

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 World,

I found a gentleman who was sneaking around our facility earlier today.  He identified himself as "Bob Philips".  After I threatened to call the police, he indicated that he was a private investigator, and was working for an anonymous individual who goes by the initials "C.S.R."

He further told me that he'd been assigned to investigate our rumored developments on a state of the art ultralight aircraft.  I told him that I was, in fact, soon going to share information on such an aircraft with the world, and I could really care less if he was taking spy photos -- if he was leaking information, I was planning to do the same thing, only a few days later.  He gave me a weird look, so I told him to scram, and he left.  Just before he walked out the door, he said:

"I know about the stitches, the thumb, and the scar on your forehead."

I have no idea what he was talking about.

Belite UltraCub (Ultralight Airplane)
Anyway, our upcoming Belite UltraCub (Ultralight Aircraft) has some really cool features:

*folding wings -- our design is improved for better storage and transport
*reduced weight -- allows use of four stroke engine without carbon fiber spars
*increased wing area -- allows for quicker takeoffs and slower landings
*increased flaperon area -- likewise
*winglets -- improves flaperon effectiveness and reduces wing drag
*four stroke engine -- far better fuel economy and great reliability
*rivet construction -- easy construction, no welding involved in kit construction
*low kit and assembled aircraft cost -- we'll have a special OshKosh price, valid until the end of August.
*unbelievably good looking finishing -- using our vinyl color process -- easy and inexpensive.  Our demonstrator ultracub has metallic paint!!
*quick assembly -- as proof, I personally built this demo plane in 'spare time' over the last four months, while doing all my other Belite tasks and working in my computer forensic consulting business... (Some people thing I'm constantly in motion... and I am.)

I'm hoping to fly it briefly tomorrow (Saturday), then truck it to OshKosh to show to the world.  We don't plan to fly it at OshKosh, but we'll have another Belite demonstrator there as well.  Please come by our booth and look at our innovation on display.

The photos are on our Flickr account, here:

http://www.flickr.com/photos/beliteaircraft/

And here a couple of the finer photos which I've decided to post on the blog.

Extended Flaperons and Winglets on an UltraCub (Ultralight Aircraft from Belite)
Four Stroke engine on Belite Ultralight Aircraft


See you at AirVenture!

James (& Kathy)

Thursday, July 19, 2012

Crazy Weird Stuff 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!


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

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

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

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

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

Without further ado, here are those photos:

winglet on Belite UltraCub (Ultralight Aircraft)

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

Your Servant Faithfully,

Bob Philips

Wednesday, July 18, 2012

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

Tuesday, July 17, 2012

Industrial Espionage continues at Belite Aircraft

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


TOP SECRET -- EYES ONLY FOR UNDERSIGNED

To:  C.S.R.
From:  Ace Industrial Spy Service, Bob Phillips, PI, acting SPECIAL AGENT
Re:   Belite's Product Improvements ----- TOP SECRET MEMO #17

Mr. C.S.R.:

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

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

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

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

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

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

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

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

How to make an ultralight look like a Piper Cub

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


How to make an ultralight look like a Piper Cub!

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

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

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

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

Completed Turtledeck for a Belite Ultralight airplane -- UltraCub
From left to right, there are six formers: A through F.  There are two window formers, and two window eave formers, four angle gussets, and four square gussets.

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

Bottom of A former is cut off as shown
Gluing the A and B formers along with the window former
Gluing the window eaves former
Window eaves after clamps removed; bottom longerons (1/4" x 3/4") placed and glued
Gluing C, D, E formers to bottom longerons
Gluing F former in place to bottom longerons
Gluing top longerons in place -- two 1/4" x 1/2" and one 1/4" x 3/4"
In the above photo, the longerons are glued using lots of clamps.  As they are bent, this will require making sure that the overall turtledeck structure stays flush to the fuselage.  You can see some big clamps along the side of the fuselage which help keep it all clamped down and square.

Use lots of clamps.
Side longerons (1/4" x 3/4") and front angle gussett glued in place.
Top corner longerons (1/4" x 3/4") glued in place.  Longeron is fitted first to butt into corner.
Top corner longerons and lots of clamps -- a recurring theme.
1/4" x 3/4" stiffener glued to back of B former.  
Angle gussett glued to top longerons on each side
Square gussett glued in place on C former.
Additional (sideways) top corner longerons glued in place, forming 90 degree angle longerons
Between Former stiffeners cut, fitted and glued in place.
The purpose of the stiffeners in the above photo is to prevent the bottom longerons from bending when the structure is covered with lightweight dacron fabric.  Of course, to work well, we need to add a second level of stiffeners:

more stiffeners on the higher level.
short longerons cut, fitted, glued and clamped in place.
90 degree square gussett on E former
All longerons trimmed off, view from front.
quartering view of turtledeck for Belite ultralight aircraft -- UltraCub.
view of rear of turtledeck.
Your turtledeck is now ready to cover with Dacron fabric.  

Friday, July 13, 2012

more spy photos

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!


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