How to attach an engine to an ultralight airplane

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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.

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

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. 21^st 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.

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

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.

  

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.

Hasking and other Reflections on Fatherhood

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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.

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.