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Showing posts sorted by relevance for query blue. Sort by date Show all posts

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


Sunday, May 2, 2010

What altitude did James reach in the Superlite???

Today was an extraordinarily beautiful day in Wichita. Light winds; blue sky; puffy cumulus. The airport was buzzing: two helicopters, a tow plane, at least two gliders, a C182, a Aeronca, and the Belite Superlite Sun N Fun winner.

I wanted to test some instrumentation; buzz a friend's house (with his permission); and test fuel consumption in the Superlite. Also, I wanted to climb a long ways up and see what the world liked like.

All successful. The icing on the cake was throwing a roll of toilet paper at my friend Kevin. (A couple of hours later: somehow it reappeared on my front lawn.)

Even though it was a T-shirt day on the ground, I wore my leather coat in preparation for much colder weather up high. When I got up there, I loitered over the gliderport for a long time. I shot video of KAAO (Jabara airport) off in the distance; and although I did not have a true altimeter with me, the video says it all. Very chilly.!



If the blog video won't open, it is also posted on youtube:

http://www.youtube.com/beliteaircraft#p/u/0/peTwoxkIxg0

How high was I?? I'd appreciate your guess.... The Jabara runway is 6101 feet long!

Please place a guess in the comments. Thanks!!

Monday, November 22, 2021

Breaking the Landing Gear Bulkhead on my Chipper 2

Stupid Pilot Tricks...

I had just installed the new oil thermostat in my Chipper 2.  I pulled the plane out of the hangar, eager for a break in the routine.  (I was early in the process of installing shock absorbers on the plane.) It was a beautiful afternoon, the sky was blue, the grass was green, and the plane was gorgeous.  

Chipper 2 N318KW stock photo, before recent events.

As usual, my UL350iS powered up without a hitch. My goal was simply to warm up the engine and check oil pressure & temps. The process of warming up was taking a long time (it was a little chilly) and I advanced power while keeping the brakes engaged.  This went on for several minutes. I edged the power up a bit more. My brakes were having a hard time keeping the plane from creeping forward. I'd ease back on the power, hold the brakes a little tighter, and advance power again.

All of this was extremely poorly thought out.

After advancing power again, the plane started to list to the left and settle down to the ground, like it was kneeling. Realizing that a prop strike was imminent, I retarded throttle. The tip of the prop cut into the soft grass and dirt, carrying through several blades before all became silent.

I broke my plane.

I did not take a picture. I was flaming mad. My hangar mates swiftly emerged from a hangar backroom, having heard the commotion, and walked towards me as I got out of the kneeling airplane and looked at one gear leg bent backwards. I realized that I had twisted the gear attach bulkhead. (The gear leg was not hurt.)

Then I realized I had forgotten to re-install the trailing links, so I had just ripped my gear out because of my forgetfulness.

With the help of my friends, we rolled the wounded bird back into the hangar. 

The inside of the cockpit looked like this:

And after several days of drilling out rivets, chopping out aluminum bulkhead, and cutting / pulling / fussing / fuming, the removed bits looked like this:

Over the course of the Thanksgiving holiday, I will be stepping you through what I have learned on how to repair this problem in my Chipper. I have also been using this opportunity to solve some other problems.

1) Improved bulkhead assembly for potentially higher gross weight

2) Shock absorber installation for potentially higher gross weight

3) Improvements in mounting techniques for bolts in honeycomb

4) Improvements in bonding techniques

5) General proof that this structure is repairable

And as I head into the Thanksgiving break, things are much improved. Here's a photo of how things were looking earlier this afternoon.


I do all my airplane stuff at 29KS, which is the Wichita Gliderport. It has many very smart aviation people who hangar there and build / rebuild / repair things there.

The benefit of this unfortunate event is that I am receiving honeycomb repair and assembly advice from another of these hangar mates. 

I'm going to take a moment out to brag on some of my aviation friends:

    N.: ex-CTO of Mooney Aircraft
    CW.: A&P/IA, formerly with Textron, traveled the globe fixing King Airs, versed in everything including honeycomb
    D.: A&P/IA, formerly built parts for Mosquito Helicopters, currently starting a Piper Cub parts company, currently rebuilding 3 Cubs, has built 7 Pietenpols lifetime to date, with the last one nearly done right now
    CP: 50 years with Cessna engineering, knows everything about any piston aircraft they designed. He can tell you why various Skylanes had weight changes, cabin changes, structure changes, feature changes. He is the walking and talking encylopedia of Cessna singles. 
    K: Designed composite propellers for McCauley, currently working for Textron special ops.
 
In particular CW has taken an interest in Chipper 2 and its proper repair. 

Bottom line: after this rebuild, I believe that the gear mounting bulkhead will be strong enough so that failure will not occur when the trailing link is not installed.

Thanks for reading. Please "Follow" this blog by clicking on the Follow button.  You'll be advised every time I post the next article.

Live & Learn.




Thursday, July 23, 2009

Blue Highways; Flint Hills


“Blue Highways; Flint Hills”


(c) 2009 by James Wiebe; all material and photos are copyright. Please link to this blog and to www.beliteaircraft.com


1. 20 Miles.

I can see for up to 20 miles, depending on which way I look. Looking south, an expanse of prairie grass heads downslope, along my impromptu runway, to a line of trees which look to follow a creek. For my miles beyond that, the terrain slowly rises and eventually disappears in a flint hills ridgeline.

To my east, far in the distance, are what appear to be cell phone towers. They are perhaps four miles away, at the top of a ridgeline. I can also see continuous green pasture between me and the cell towers. The landscape is typical of the flint hills. It is beautiful, and alive. I hear the constant buzzing of insects. Earlier, after my airplane came to rest, a group of cows stared at me. They wondered if I had brought Alfalfa pellets. No, I hadn’t, and they wandered off.

Just a couple of hundred yards to the north, the land forms a grassy knoll and then the terrain disappears behind the back side of the knoll. The cows went that way.

The terrain to my west is grass, with a road far off in the distance. I see a car on the road; it is visible because it is traveling rapidly and raising a ball of dust. Later, I will decide to hike towards that road.

I have a Garmin GPS, which is very helpful. It tells me that five miles away, is the Kansas State Turnpike, I-35. To my south, about 1.5 miles away, is county road 50. A line of trees that I mentioned in that direction, and I’m not sure if the road is before or after the trees. Is that creek over there as well? I have no idea, and the GPS doesn’t offer that clue.

Now I am attempting a hike northeast, towards county road 70 on the GPS. I can’t get to the road; I am stopped by another creek. The creek was slightly flooding as a result of heavy rains a day or two ago. I could have crossed it, but it would have meant soaking my ankles. I see a tree which has fallen perfectly across the creek. Considering giving it a try; but NO, I don’t want to risk soaking myself, my Nikon D300 camera, my GPS. So I head back to the airplane.

I am in the middle of the flint hills. I am sitting on the wheel of my airplane. It is sitting at an odd angle, with the left wingtip 6 feet above the ground, and the right wingtip one foot above the ground. I’ve pulled the seat pad out of the airplane, and I’m using it to keep some cushion between me, the wheel, and the grass.

There are no roads here. There is no airport. I am here. My airplane is with me, sitting, wounded.



2.
Formation flying.

The day started with last minute details for a flight to Airventure, Oshkosh, Wisconsin. We wanted to fly our demonstrator airplane up, as a promotion for our new aircraft and our new company, Belite Aircraft.

My friend Terry Alley and my coworker Gene Stratton had been working with me at Jabara airport (KAAO) to make some last minute tune-ups to the bird. We’d installed a rudder trim tab because of nagging right foot pressure, and that had solved a problem. The plane had been loaded. The electrical system on the plane was acting up, probably due to a bad voltage regulator. In a fit of disgust, I had disconnected the voltage regulator. Electric operation is not a necessity in an ultralight.

Our demonstrator airplane was flying nicely.

Terry and I took off in a formation flight towards Emporia. It was an extraordinarily beautiful morning! Blue skies. Occasional radio calls. A little maneuvering for photographs on the part of Terry. As we reached Cassoday, KS, I no longer hear from him, and decide that he has headed back home. He’d told me he’d break off there.

The plane is remarkable, and has a gas gauge which shows my fuel quantity. It showed a full tank at the start of the flight. I had ‘tankered’ an additional 2 gallons of fuel so I could land and refuel anywhere, if necessary. (FAR 103 regulations prohibit a tank capacity of more than 5 gallons).

My fuel gauge hung on full for a while, then started to descend a little too quickly through ¾, ½, and down to ¼ tank. Over the flint hills, there are few options for roads, but many options for pastures. Even though only 8 miles short of the Emporia airport, I determined that the smartest thing to do would be to make a landing, refuel, and finish the leg. (Why was the fuel consumption so high? Probably an incorrectly set carb. We’ll figure that out after Oshkosh.)

I decided that instead of staggering into my Emporia on fumes, I’d make a precautionary landing and resolve the issue.

You are probably thinking that the airplane broke on landing, because of a rock or cow turd. Not so… the landing was silky smooth; the plane floated onto the field of grass as if I had edged onto a down pillow. It was smooth.


3. Landed on the prairie.

I’m grinning. I don’t even shut the engine down; it idles smoothly as I refuel the plane.

After adding two gallons of fuel from my spare tank, I tried to take off.

Trouble; I can’t get enough airspeed. The grass is a little high and I may have a touch of tailwind. I try to takeoff twice; it doesn’t get airborne. However, I’ve got several degrees of downslope on the hill, and I can taxi up the hill for a long ways; no problem! I can resolve the takeoff speed issue.

Turning around, I headed up the hill. As I approached the spot to turn around and try again, my right main gear axle sheared off. In a quarter second:

The right landing gear collapsed as the tip of the steel, now without a wheel, punched into the dirt, and bit hard.

The propeller disintegrated. All three blades snapped off.


Dirt was thrown on the plane as the propeller augured through the ground.

The engine quit, now.

The right wingtip of the plane hit the ground, bending a clip.


“Well, that’s that”, or something to that effect went through my head.

Stunned.

Unhurt.

Bewildered.

The plane is completely undamaged, except for the prop, the right gear (it looks like a pretzel), the bent clip and unknown engine damage, if any. There is absolutely no damage to the fuselage. The gear attachment points are unharmed.

Already considering what’s and why’s.


4. Cellphone service.

I pull out my cell phone and call my wife. Over towards the northeast, I can see the cell phone tower which is almost certainly carrying the signal to my wife. The connection quality is perfect.

I’m bright and cheery as I talk to her. She asks if I'm at Emporia. No... I carefully explain the sequence of events. She is not angry, (for instance: why did I try and take this trip in an ultralight?!) but seems just pleased that all has ended well. She and I begin to strategize about how to get the plane back to Wichita, so it can be trucked to Oshkosh. We agree to leave the retrieval task to our able helper Gene Stratton, also my friend Terry Alley.

A weird thing happens. A few moments later, my cellphone rings. I look at the caller ID, and it is someone calling from CRU-WiebeTech, my old company. She is of course completely unaware of my circumstances. She has a marketing question. I answer it, I consider telling her what has happened, I think better of it. I say nothing about my where and why I am.

4 hours pass.

I took a hike. I got sweaty. I rue my decision to not pack any more water in the airplane. I had one diet Dr Pepper, and it is long gone.

My daughter calls me (my cell phone service continues to be perfect.)

To quote Bill Curtis, “I found the internet!”. My USB dongle and my laptop computer works great, and I get caught up on my personal email for the first time in a while. I send an email to Don Hackett, at Wichita State University, hinting that I am in the middle of the Flint Hills with a big story to tell. He emails me back, saying he can’t wait to read it, that it will certainly entertain my grandchildren some day.

Since I am back at the airplane, I work on the computer while I am sitting either on the airplane tire (the good one, not the snapped one) or by sitting on a cushion on the ground. I consider that if I had to spend the night, I could do so, as I brought a sleeping bag. But I do not consider the ticks. Hours later, when I was safely back home, I look at my ankles and see that they are covered with small ticks. Dozens of ticks; even smaller than a pinhead.

I’m told by my wife that Gene and Terry are coming, also my daughter, Jennifer. If they can get in the pasture, we’ll have no problem dismantling the wings and loading the plane on a trailer.

There they are, driving across a sea of green grass.

Please hand me a bottle of water.


5. Those last two italicized lines were a fantasy.

Gene, Terry and Jennifer are not here yet. It is late afternoon, and I am very thirsty. My cellphone continues to work great. Kathy and I continue conversations on marketing and logistic issues related to the upcoming Airventure show.

Jennifer calls and texts me, they are very close to me. I have picked a flint hills pasture which is several square miles in size. They have found a locked gate. They want to know if they should find someone with a key first, or hop the fence and bring me water and food. I ask them to hop the fence. I think they are about a mile east of me; if I walk towards them, and they walk towards me, we’ll meet, right?!

I’m eager for the water. I stupidly leave my cap and GPS at the airplane, but I do take my cellphone. I start hiking east. My wife calls again, and I explain what we are trying to do.

About 20 minutes later, I see two dots far away. One is wearing a bright orange shirt – that’s got to be a Belite T-shirt, which is one of our corporate colors. The other is my daughter. I call Gene. He can’t see me, but I can see him plainly. I tell him to turn left 45 degrees and walk towards the sun. He proceeds to do so, then his image dot disappears as he descends into a gully. I also descend into another gully. 15 minutes later, we are both out of our respective gullys, and finally in sight of each other.

When we finally meet, he and Jennifer are on one side of a barbed wire fence, I am on the other. He hands me a bottle of water. It is gone inside me immediately. He hands me a Diet Dr Pepper, which is still cold, and a cheeseburger.


6. What does an Angel look like?

We have to figure out how to get the trucks and trailer from the locked gate, across a pasture, a mile to the East, over to the barbed wire fence, through the fence, to the downed aircraft, a mile or more behind me.

My friend Terry remained at the locked gate, then went looking for someone with a key.

While all of this is being considered, Gene spots a pickup truck driving slowly across the flint hills, inside the pasture which contains my airplane! He hands me his hiking pack, and takes off quickly towards the truck.

Jennifer and I walk at a more leisurely pace towards the truck.

Gene catches the truck, when Jennifer and I arrive a few minutes later, Gene is sitting in the cab with our Angel. His name is Calvin, he works for the landowner, and he is here to feed the cattle. He was unaware that a broken airplane is in his ranchland. He is eager to help.

Calvin helps us – taking us through a gate in the barbed wire fence, then to the locked gate beyond the next pasture. He reaches in his glove compartment, pulls out a key, and a moment later the gate is open. Our aircraft trailer is sitting there (it’s actually Terry’s) but Terry’s truck is gone. We can’t get him on the cellphone. He’s out looking for a key; but we already have the gate unlocked. Gene and Calvin drive off, looking for Terry. Jennifer and I get in the company pickup truck, which we turn on and crank up the AC. We talk. We smile. Jennifer is so glad to see me.

Eventually everyone returns. Terry has found some other people, who were trying to get ahold of Calvin. (We already found Calvin.) We all head back towards the downed aircraft. There are three pickup trucks and one aircraft trailer heading across a cattle road in the flint hills. Calvin knows the pasture extremely well. He tells us they recently had heavy rain; he keeps us from heading down gullys.

Soon the work begins on dismantling the aircraft.


7. The cattle watched, and a plane went back to Wichita.

The landowner and his wife show up. Another lady shows up. A child is along with the couple, cheerfully tossing alfalfa pellets from the back of yet another pickup truck to the cattle, who have also showed up. There are a great many cows, all milling around the pickup trucks, the airplane, and the people.

There isn’t a great deal of work involved with disassembling this airplane. The wings unbolt, the flaperon cables unclip, the flaperons also unbolt. In about an hour and a half, the airplane changes from wounded to disassembled and stored on the trailer and one of the pickup trucks.


3 hours later, we are back in Wichita, at our workshop.


8. Grateful.

I had the opportunity to muse on things which I am grateful for, and people rose to the top of my list. First of all, to my wife, who shares this adventure with me. To Gene, who has become more than a coworker. I value his counsel and ability to get any job done. To Terry, who quickly has become a great friend. And of course, my daughters, who are intelligent and loving. Thank you Jennifer, for your insistence on being part of the rescue squad.

I am especially grateful to Calvin and the others who helped us get the plane out of their grazing land. Thank you! I’m sorry I didn’t get all your names. Your cheerfulness and desire to help made an indelible, wonderful impression on me. I was worried that I had landed in your pasture. You were simply pleased that I wasn’t hurt.

Finally, I am grateful to God, whom I believe in. The gear was destined to fatigue and shear off, sooner or later. It could have happened while landing on concrete, or it could have happened while taxing around in the flint hills. My demonstrator plane will be at Oshkosh, hardly the worse for wear, but it’s not flyable until the engine is torn down. The shaft still turns freely, but there clearly is a raspy feel to it. Cracked bearing? Bent crank? We’ll see. Also, we'll redesign the wheel axle shaft immediately to improve strength.


9. Final thoughts?

Whose fault was this? I’ll stop the debate right now – it’s entirely mine. Inadequate fuel planning; perhaps improper carb setup; inappropriate landing location. The plane handled the situation with sweetness amidst difficulty.

I WILL NEVER FORGET THE FEELING OF SITTING IN THE AIRPLANE, SUCCESSFUL, AFTER SOFT UPHILL LANDING, WITH ENGINE IDLING, ON THE FLINT HILLS PRAIRIE, SOAKING IN TO ME...

William Least Heat Moon writes of Blue Highways. This was mine.

--- James Wiebe, written somewhere in the flint hills near Olpe, Kansas, and completed the following day. Wednesday, July 22, 2009, and Thursday, July 23, 2009.

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.


Sunday, July 10, 2011

An Aluminum Dream

(There is news far below of a new aluminum version of our plane.  Read down...)

***

I've had a dream.  In it, I'm able to take a simple board, lay it across my chest, and in a few steps I am flying.  Somehow, I lay on the board, and it generates enough lift to take me above trees, mountains, streams, and beautiful things.

I do not understand how this can be.  I am not Jetman, but I know that it is real, and in my dream, I am gliding down over a descending landscape.

I am able to breeze by trees, houses, birds, and under a clear, blue sky, I am able to select a landing spot.  In my dream, I land just a few minutes after I take off.  Sometimes, I have a passenger nearby (I do not understand this either.)  But mostly, I am free, and I simply fly.

I feel the joy, and I am determined to share it with others.  I see that as a role given to me:  to spread the joy and the ability to fly above and observe above and be above.  To be above.  To fly.

***

Two days ago, I was down in Tulsa, Oklahoma, making some simple wiring fixes to a plane we'd delivered to a new Belite owner.  The airstrip was overkill long at 1320 feet; there were horses on either side, and the hangar was in the back yard of the house.  Ironically, a windsock was 3/4ths of the way down the strip, and it was positioned nearly in the middle of the runway.  I asked the owner if I could once again fly the plane that was formerly mine, and he said, of course, 'yes'. 

Once around the pattern, a low approach. 

Another time around the pattern.  A hot day.  But 300 feet above the ground, things were comfortable in the open cockpit.

A second time around with a lineup to final approach.  A good breeze out of the east.  A crossing landing on the runway, drifting from left side to right side, making advantage of the crosswind.

Landing.  Barely disturbed the grass blades -- a combination of luck, maybe some skill, some springy gear, and some big fat tires.

Out of the plane.  My wife took my picture, as did one of the new owners.  The other owner showed up late, I started the engine just so he could see it easily start.

***

He called me earlier today, and I answered.  I am in West Virginia, getting ready to deliver a series of talks on computer forensics at Marshall University.  He wanted to know how to adjust the tension on the throttle lever; and I gave him some quick advice.  He'd flown the bird, rechristened 'Queen Lady', and he was tiring of readjusting power continuously.  Surely, an understandable aggravation.  But he'd flown around for 30 minutes, and I was pleased for him.

***

Two planes sold in 24 hours -- that's news.  One heading to California, the other to Missouri.  We cut the prices on some of our planes in order to reduce inventory, and in order to prepare a way for a new aluminum variant.

***

I've always been in love with technology.  I enjoyed putting carbon fiber spars on ultralights -- I thought the strength / weight thing was simply amazing.  I ignored the economics -- figured people would pay.  A few did.  Not many.

***

Kathy and I put out a pricing survey on our planes.  It seems these are the most important things to many of our potential customers:

a)  They like our plane.
b)  They want to fly.
c)  They want to afford our plane.
d)  They may weigh a little too much -- but they still want to fly.  Do we have a plane that will accommodate them?

***

Belite has been in development of an aluminum fuselage of our plane.  An original prototoype was built, and we did a series of tests on it: 

a)  Engine mount strength
b)  Pilot seat strength
c)  Airframe strength -- taxiing  (super hard jolts while going up and down the runway without shocks).

Engine Mount Strength -- over 400 pounds of steel.  Ken needs to smile.

Pilot Seat test -- 819 pounds of steel and sand
Well, I broke the plane while doing initial taxi and flight test.

So we redesigned the cabin area, and a bunch of the round tubing was replaced with square tubing -- much stronger.  It ended up looking like this:

Closeup of square aluminum tubing

So here's a photo of an aluminum airplane.  Notice the heavy cockpit structure, also the monocoque aluminum skin on the sides, (carrying landing loads).  The landing gear is chromaloy steel, and the engine mount is also chromaloy steel.  The aerodynamics are largely undisturbed from our sweet flying, original 254.

Aluminum Fuselage Ultralight Airplane from Belite Aircraft


***

Pricing to be announced at Oshkosh on these models:

a)  Aluminum Belite 254 taildragger with 28HP engine.  Weighs about 210 pounds.  UK SSDR compatible as well!
b)  Aluminum Belite 254 Trike with 28HP engine.  Weighs about 220 pounds.  UK SSDR compatible as well!
c)  taildragger with 45HP engine.  Weighs less than 254 pounds.  Phenomenal takeoff performance.
d)  same thing in Trike.
e)  deluxe taildragger with 50HP engine, carbon fiber, 'chute, every option we make. 
f)   deluxe trike with 50HP engine.

And yes, we're still working in the 4 stroke engine.  And the aluminum kit version.

***

Many of our potential customers are concerned about their weight in relationship to our planes.  These new aluminum planes solve that problem. 

The 45HP engine, in combination with the lightweight aluminum fuselage, provides the ability to lift a lot of load!  We can now handle pilot loads up to 275 pounds in the taildragger configuration.  With really great performance!

***

The aluminum fuselage airplane pictured above has already been presold to a customer.

***

We have two more fuselages already started.  We will have at least one aluminum ultralight at Oshkosh.   Please come see us.

Sunday, December 6, 2009

Shearer

“Shearer”
© 2009 by James Wiebe

[Jason]
My friend Jason weighs 235 pounds. He is tall (nearly as tall as me) and strongly proportioned, far more so than me. If he was a football player, he would be a wide receiver. He used to wear a beard that made him look like Abe Lincoln. In fact, when he was pointed out to me many years ago, the mutual friend told me to look for the man who looked like Abe. I found Jason easily, and we became lifelong friends.

[1996 – summertime – at Shearer, which is somewhere deep in the Selway-Bitterroot Wilderness]
I am staring at Jason as he runs at full gallop across my field of view. Just like Indiana Jones, each step he makes is kicking up dust, and it is hard to imagine someone as large as him running as fast as he is. Why is he running so fast? He is running from my left to my right.

Further to my left is a blue and white Cessna, which is sitting near the end of a wilderness airstrip. Far off to my right is the Selway river. If Jason keeps running as fast as he is, he will run into the river. Jason is running from the airplane as fast as legs can carry a man. I have never seen anything like it.
He stops, and I jog over to him. He is looking at his hand. It has four stings in it. Even in the space of 25 or 30 seconds, the stings are forming considerable welts.

“I was last stung by wasps when I was a child,” he says, “and I may be allergic to these stings.” That’s not good news. We are miles from roads, trailheads, human beings, help, doctors, and civilization. We had just arrived in my Cessna Skyhawk, we had just gotten out of the airplane. Jason was in the process of twisting a tie down stake into the dry, sandy soil so that we could tie the plane down.
He had stuck the stake into a convenient hole in the ground, in order to save a little time, and the wasps had flown out and bit him. Only four made it in the instant of initial attack, and Jason’s quick run had left the balance of the wasp pack behind. But four stings in one hand!

We need a doctor – Oh wait, Jason is a doctor, and he tells me what to do in case things go poorly for him. There really is precious little we can do except watch his hand and pay attention to his breathing. My anxiety level rises.
He and I twist the remainder of the tie down stakes into the ground. We don’t put them into any other wasp nests; no more stings.

There is a small cluster of pine trees alongside the runway which provides an ideal camping spot. We set up our tent.

Jason’s hand is swollen and painful. We have the ideal solution to get his mind from dwelling on the hand: flyfishing. That’s what we are here to do. We can fish, and he can dip his hand in the river anytime to cool it off.

We proceed to fly fish in the Selway river. The wilderness fishing is remarkable; each spot of open water provides a new opportunity to catch more trout. Later, we find a deeper hole. Every time our fly hits the water, another round of fish race toward it. Only one wins; the others return to the depths to await another chance. We catch and release the native cutthroat trout, one after another.

The day wears on. Jason and I hike up and down the river, exploring the wilderness. We return to camp, make dinner, and sit around a fire. The sun sets; I see one hundred thousand stars against a flat black sky. Then it’s time to crawl in our sleeping bags.

The next morning, Jason’s hand is the size of small ham.


[24 hours before the wasp bites]
We had arrived in the small town of Salmon, Idaho, having flown 999 statute miles from Wichita, KS. We were thrilled. I took mountain flying training earlier the same year, and I am eager to deliver Jason and myself deep into the wilderness. Our destination, Shearer airstrip, has been carefully selected from a mountain flying guide. Although I’ve never flown to Shearer before, a qualified mountain flying instructor has agreed to take me specifically to this remote airstrip to train me on its intricacies. Like most good mountain airstrips, it’s in a valley, also along a river, and is a one way in, one way out strip. In other words, you can only approach from one direction for landing, because the airstrip ends in a side of a mountain or some similar impenetrable obstacle. Takeoff is in the opposite direction for the same reason. Prior instruction is a very good idea for the first time pilot. And I had arranged that instruction.

My instructor was used to flying large airplanes, and my airplane was small, and liked to glide well when the power was reduced. This would be a problem.
The approach to Shearer airstrip will fill anyone with awe, first because of the beauty, and secondly, because of the intricacy of lacing the aircraft through the valley and into the airstrip.

At a normal airfield, the proper pattern for landing is a rectangle. You enter the rectangle and trace its outline, you descend in an orderly fashion; you land. This doesn’t work at Shearer. As I mentioned, Shearer is in a valley. There are no rectangular traffic patterns at Shearer.

A proper approach to Shearer requires a descent into the Selway river valley. A good route is to come down Bear Creek, then turn left (upriver) to head towards Shearer, immediately after passing a private ranch, with a private runway; a small oasis of private ownership surrounded by the wilderness. The ranch briefly provides a glimpse of extraordinary wealth – causing an inflective thought as you consider the difficulty of access combined with the beauty of the location; the perfectly green grass runway, the solar cells for power generation. Who could afford to own this? How was it built in this remote location? The ranch quickly recedes behind you.

You continue to fly over the river valley at an altitude of perhaps five or six hundred feet off the water. You see crystal water rushing over boulders below you, and you see mountains on both sides of you. They move by with impressive speed; always that feeling of speed in your peripheral vision. Trees rush by. Mountains rush by. You keep the airplane roughly on the right side of the valley, because, an airplane may be around the corner, coming in the opposite direction, and there are right of ways which should be observed, even for airplanes. So you are a little closer to the scenery of the right side of the valley, and it is perhaps the closest you’ve ever been to a mountain, while moving so rapidly through the air. You have to remain observant, because the valley is making slight S turns as the course of the river, the mountains, and the trees moves around.

So here’s the next problem: even though the airstrip is close (perhaps two miles away, upriver), and you are rushing toward it, you still can’t see it. It is in the valley, but the river turns sharply, and that will require the airplane to make a sharp right turn as the river does likewise. The approach is therefore difficult and blind. When we get to the proper ridge, we will turn right, and only then will we see the runway. And it will be right in front of us. And when the runway is right in front of us, we’d better check for elk and deer on the runway. If they block our way, we had best apply power, climb out in a slight left turn, and gain altitude over the river heading upriver. This decision has to be made immediately, because when the airplane is committed to land, it will be impossible to change our mind. (A last moment climb out will simply cause us to hit a mountain which lies at the end of the runway.)

Remember, I’m with an instructor for this first attempt, right? Nothing can possibly go wrong.

The airplane has been slowed to about 65mph, and we have some flaps extended, even though we still can’t see the airstrip. We are fully configured for landing. The ridge appears ahead and to the right. I bank the airplane to turn over the ridge, and I see trees shooting below me as I cross the ridge line.

Sure enough, the runway is there. It is the narrowest, most unimproved slit of ground I’ve ever landed an airplane on. It looks exactly like a jeep trail. The only thing going for it is that it is straight. It rises slightly upslope towards the far end, then the terrain rises even faster into a mountain side.
It is also very short. This makes things a little trickier yet, simply due to the lack of room for error. Don’t land short (there’s no runway – just weeds and mountain pasture). Don’t land long (it’s a mountain, idiot.) Just land at the right spot, and do it the first time, everytime.

We are very close to the approach end of the runway. The instructor had me cut power to the engine, and so we are essentially gliding towards our touchdown point.
My little airplane is a Cessna Skyhawk, also known as a 172. They are fun, sprightly little flyers. They hold four people, and are also commonly used for instruction.

My instructor’s regular job is hauling passengers and freight in larger aircraft, such as the Cessna Stationair. A Stationair will not glide well. My instructor has forgotten that the 172 we are in is NOT a Stationair. My 172 is gliding very well. In fact, it is gliding so well that we are both realzing that the plane will not get onto the ground before we run out of airstrip. And there is a mountain beyond that.
About 2/3rds of the way down the airstrip, the wheels of the plane finally touch the dirt. The instructor and I both press the wheel brakes as hard as legs will press. The 172 wheels grab dirt and sink and skid as the mountain in the windshield gets larger. (We’re skidding towards it). Mercifully, about 75 feet of dirt and sand remains as the airplane finally skids to a stop.
I exhale. So does the instructor.

“I think we should try that one more time,” says the instructor. I agree. We turn the plane around, take off, head downriver, reverse course, and come back in and land one more time. With better speed control, the next landing is perfect, and my instructor tells me that I’m hereafter OK to do it in on my own. We fly back to Salmon, and I’m glad to be done with him.

Jason is waiting for me at our hotel room. He’s been shopping for food while I’ve been staining seat cushions. We will reload the plane and depart for our remote camping destination in the morning.

***

--- James Wiebe

PS I've been super busy working on stuff. Hope you enjoyed reading this little interlude from my past. It's basically an uncompleted true story -- I started to write a book about these experiences several years ago and this would have been one of the chapters. My friend Jason is awesome. We've done many adventure trips over the years.

Saturday, January 8, 2022

Details on Ultralight Honeycomb Cabin

I'm now 34 hours into the build of a Chipper ProCub / UltraCub 2022 prototype aircraft. The design has the following characteristics:
  • Safety first, with an enclosed robust cabin
  • Compliant with FAR Part 103
  •     - single seat
  •     - empty weight of 254 pounds
  •     - stall speed of 28 mph or less
  •     - full power cruise speed of no greater than 62 mph
  •     - maximum fuel capacity of 5 gallons
  • Easy to build
  • Classic good looks, unapologetically an airplane 
  • Inexpensive
  • Quick building
  • Folding wings
  • Fantastic flying manners
  • STOL capability is a plus.
 A shoutout to my friend Landon!, who painted the seat in the photo. This seat was made for and first flown in my skydock design, and it looks great with the old Belite logo and gloss blue color. Everytime I do work on an ultralight, I find this seat and set it in the design to see how things are shaping up. I do have a list of brief skydock videos,


but I digress. Back to the business at hand. Here's the visual progress report on this Saturday:


Below is a closeup on that seat. It is resting on two honeycomb bulkheads, along with the backrest honeycomb cross piece. The honeycomb has been cleaned up with an aluminum cap on the heavier 3/4" rear bottom honeycomb and backrest cross piece. The front cross piece has a vinyl cap. Look carefully into the small 'windows' in the sides of the cabin, and you can see where I've begun to install aluminum tape over exposed honeycomb.


Another photographic point of view. The cabin is currently in 'flintstone' mode as the bottom skins aren't yet installed.




Yesterday, I designed a couple of new gussets for the top of the cabin. They are highlighted in green:


Today, I cut them on the shopbot and installed them. Here's the forward gusset. You can see the mirror part on the opposite side of the cabin as well. I pre-primed them before I installed them. The tab is intentionally overbent to keep the sharp edge away from the pilot-occupant.


For that matter, all of the gussets are bent with safety in mind. The tabs almost always face away from the occupant.

I already mentioned the backrest cross support piece. It is fabricated from 3/4" honeycomb, and then held in place by pairs of aluminum angles which were bonded using epoxy. I prefer 3m 2216, but I had original formula JB Weld on hand, so I used it.


The photo shows the parts bonded together and held with temporary bolts. As the rear fuselage side skin is not yet installed, these bolts will eventually be replaced and redone with washers along normal practice lines.


Changing my focus to the front box, I'm really pleased with the quality of the CNC parts; the general fit, and the way this is beginning to look. I'm excited for how things will be when the windshield and engine cowl are added. I'm designing a new cowl which reflects the fresh new look of this airplane; I won't be using the old radial bump design anymore.


I mentioned earlier that the cabin was still in flintstone mode (no bottom skin yet); these photos show the detail of the structure as seen from the bottom.



Make sure you've seen my youtube videos which show this evolving project:

This one talks about adding metal skin to the rear fuselage in CAD:

This one talks about using Sketchup to make this design:

Finally, as I am in bootstrap mode, I get a lot of enthusiasm and deeply appreciate my patrons. $10 per month gives you the rights to the blueprints for this plane (terms and conditions apply) and $35 per month indicates that you plan to purchase a kit. $80 indicates that you plan to purchase a Ready To Fly; I've set the price for the first 3 RTF planes at $30,000 in taildragger configuration and basic instrumentation.

Become a patron here:

www.patreon.com/jameswiebe

Thanks for reading,


P.S., this is how the cabin CAD looked on December 12, a little less than one month ago. It's come a long way!



























Wednesday, September 21, 2022

Electronic Production Inflation Blues

I took nearly 3 weeks off. The time was spent communing with moose in Wyoming. Yeah, really, ran into 3 of the critters over the course of my camping trip.  One got very close to the blue chair that I was sitting in, and a few moments later I took this pic.

Nice lady, isn't she? She's a pretty big gal, and she's definitely looking at me. Defnitely looking bigger than I remember moose to be.

Which, of course, naturally leads me to my topic of inflation & a small electronic business. (Sorry for the abrupt turn.)

I've seen social media posts talking up a general mistrust in "supply chain issues", especially as it relates to electronics.  Such as electronics for automotive production, or in my case, experimental avionics. Some people mock the reality of these issues.

Here's my reality.

Around two years ago, I started using a very accurate air pressure sensor, as a basis for the air speed sensor within my line of aircraft instrumentation. Drilling down to the exact part in question, it is a Honeywell SSCDRRN100MDAA5.  It accepts a Pitot line (from the ram air) and also a static line (used to establish the differential pressure), thus providing a basis for digitization and eventual display of airspeed in the cockpit of the airplane.

Here is the invoice from two years ago:


And you can see that I paid $31.52 for each sensor.

Here's the invoice from today, as I bought parts to fill orders from customers.

Over the course of 24 months, the price has gone up from $31.52 to $53.79, an increase of 70% on this part. 

Yes, I bought less. And other electronic distributors are posting lower prices than Mouser, from whom I most recently ordered.  But the other distributors have zero stock.

You can see this for yourself by using the global chip finder which is:  FindChip.com, and inserting the part number SSCDRRN100MDAA5 into the search field.  Every part in the distribution system on the planet will show up.  Most distributors have zero stock; the ones that have parts have high prices.  Pick your poison: ship nothing and suffer; or buy parts and kill your margins.

Meanwhile, I have not passed any cost increases on to my channel or distributors. And I'm going to be the bad guy by eventually passing these increases on... except I'm not.  I'm just a small businessman trying to maintain margins, on average, across the board.

Which gets me to the bad news: The promotional prices for Radiant Instruments Gen-2 instruments ends at the end of September. Our older instrument product line will also go up in price starting October 1.  As of this writing, Aircraft Spruce has placed some orders at lower prices, and so they will be receiving some stock of our classic instruments (for instance, Radiant Turn Coordinator) and will be able to honor older pricing while their inventory holds together.  You can always find out what's in stock at Aircraft Spruce by searching Radiant in their website search bar. Most of our product line comes up, and things that are in stock are identified.

Arrgh.

Back to production tasks, now.  I promised Kathy that we would ship some orders tomorrow. 

...Hoping to repair the gross margins next month as prices go up. Hoping people still buy my stuff.

Best Regards,






Monday, March 18, 2013

Construction of Tail Feathers

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!


Aerodynamic Tail Feather construction for a Belite

We'll cover both pieces of our horizontal tail assembly in this document:  the elevator, and the horizontal stabilizer.

Construction of both pieces is very similar.  Please refer to the blue prints for layout dimensional information.

Prior to assembly, all wood pieces are sanded and deburred.  Steel and aluminum pieces are cleaned.  Steel pieces are also painted, except where glue joints will be.  (We cover the steel pieces with strategically placed masking tape, then spray paint is applied.)

Let's start with the elevator.  We use 3M 2216 glue to attach the wood ribs to the elevator spar.  We also glue tail end gussets to the end of each rib using high quality wood glue.

Elevator Assembly already under way.
The trailing edge is fitted into place.  It will fit snugly over the wood ribs and gussets.  The trailing edge usually has a plastic film both inside and outside; remove the film.

Trailing edge being fitted over elevator.
Still checking fit of trailing edge.
Trailing edge cut to length.
Now it is time to install the four bolts, one on each torque arm.

Bolts added.
Use rivets to hold the trailing edge in place.  Rivet washers are also used on the underside.

Trailing edge riveted in place.
The wood strips are prepared by gluing in spacer blocks.

Wood strips and spacer blocks, glued together.
The wood strips are then glued to the wood ribs.

Wood strips glued to wood ribs.
Closeup of clamping detail.
Two pieces of trailing edge material are cut to fit in the center section.
Preparing the center section trailing edge.
More preparation.
Glue the balsa block on each end.  Make room for the top of the bolt.  Also, unlike shown below, it may be helpful to pretrim the outline of the rib in the balsa.

Balsa block glued.
 The center section must also be riveted in.

Riveting in the center section trailing edge.
Adding more paint.
Alternate viewpoint.
End balsa cap, ready to be rough cut to shape and sanded.
Insulating Foam injected around blocks to add stiffness.  Trimmed flush after setting.
Center section cleaned up very nicely.
 After everything is sanded, apply at least two coats of varnish before covering.

Varnish the wood!

 Next, we'll finish up the horizontal stabilizer.

TO BE CONTINUED....