Wednesday, April 4, 2012

Belite Ultralight Aircraft For Sale

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This aluminum ultralight airplane is available for April delivery from Belite.  It has been finished with a gorgeous cub yellow paint job.  There is no finer ultralight aircraft made by anyone! 

Taildragger Ultralight Airplane from Belite, in Cub Yellow, for sale
It still needs three days assembly work for us to finish it.  It also is ready to accept any engine, and is a legal ultralight under FAR Part 103.  It is offered with a Belite Electronics panel, with AGL, ASI, EGT/CHT, and Inclinometer.

I checked weight on it yesterday, and what you see weighs 165 pounds.  It will take about 20 pounds of material to finish it (not counting engine/mount/prop).  So any engine / prop combination of around 69 pounds or less will work.  (For this plane to be ready to fly, we need to install the interior control cables, gas tank, windshield, flying wires on the tail feathers, etc...)

This means the F33 28HP engine will work great (just like our WoW plane or the MythBusters plane).  With the F33, we would have plenty of weight allowance to put a top cowl on the rear fuselage, and make it look quite 'cub-like'.  Just a thought...

With the Hirth F33 engine, this aircraft is offered at $25,900.

Here is the 'as-configured' info

Base aircraft with aluminum fuselage ...  $16,500
Metal priming ...  $1,000
Disc brakes ... $700
Spring gear ... $400
Lightweight Lift Strut (2024T3) ... $400
Complete fabric and paint ... $6,900
     Total .... $25,900   FAF Wichita

(Electric Start / Battery / Cowling are included)

Front view of Belite Ultralight Airplane for sale
Straight on front view of Belite Ultralight Aircraft for sale
Quartering view of Belite Ultralight Airplane for sales

End view of Belite Ultralight airplane for sale
View of wing and flaperon on Belite Ultralight Aircraft for sale
Tail Feathers on Belite Ultralight Airplane for sale
Underside of Belite Ultralight Aircraft for sale, note disc brakes and spring gear
Cabin interior, note metal priming, on Belite Ultralight Aircraft for sale
This airplane would also be phenomenal with the MZ-201 45HP engine ($2900 swap), but you would also probably need to add a ballistic parachute ($3300) to make legal weight. 

Call or email us with your questions.  (316) 253-6746  or info@beliteaircraft.com

Tuesday, April 3, 2012

Incredible paint job on new Belite

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I've just loaded about 30 hi res pics to Flickr of a new customer airplane.  You can see them on our Flickr channel, here.

This is such a nice plane!

Turqoise Belite Ultralight Airplane
It was built with nearly every option -- from a nice instrument panel to a big 50HP Hirth.  It has carbon fiber spars, an aerodynamic tail, a rescue chute, and much more.

It meets Part 103, weighing in at 275.4 pounds.  (Limit is 278.)

Here's a front on view, showing off the engine:

Front view of Belite Ultralight Airplane, with 50HP Hirth

And here's how Belite Electronics look, in the panel.

Instrument panel in Belite ultralight airplane



This plane even has strobes and position lights:

Strobe and Nav lights on Belite ultralight airplane
The interior pilot seat looks very sharp.  We haven't yet put the carpet on the floor, but that's coming too.

Interior of Belite ultralight airplane

There are many, many more photos showing all kinds of details of this airplane on Flickr.  Have a look.  Let me know what you think.

Sunday, April 1, 2012

How to attach a rear fuselage to a cabin on an ultralight airplane

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I occasionally publish portions of the Belite assembly manual, which will help you build your very own ultralight airplane.   Here we go with another installment:

Mating the Rear Fuselage to the pre-welded Aluminum cabin

In this section, you are going to mate your rear riveted aluminum fuselage to the cabin.  This is done by leveling both sections very carefully, trimming the length of the aluminum longerons on the rear, and then riveting on gussets.

This isn’t too tough to do, let’s get going!

1.      Level the cabin and the rear fuselage.  Using blocks and a level, ensure that the top of the cabin is level.  Although only one level is used in the photo, make sure it is also level side to side.

Figure 1 -- Level the cabin
You’ll notice the small stubs pointing backwards on the photo above, along the bottom of the fuselage.  Current production cabins no longer have the stubs.  

Figure 2 -- Level the rear fuselage

2.      Trim the longerons on the rear fuselage.

All four of the rear fuselage longerons are trimmed butt flush to the cabin.  Also, the top skin will need some trimming to make it fit.

Belite -- Reserve Grand Champion Ultralight at Sun N Fun 2012

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YES, we did win the Reserve Grand Champion ultralight aircraft award at Sun N Fun 2012.

3rd year in a row with a major award for Belite.

Thanks to Mike R. for doing the vast majority of the work and providing zillions of great ideas on this award winning airplane.!

Thursday, March 29, 2012

Really Cool WoW Plane Photos

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I've just got pictures today.  Here's some more photos Gene took today at Sun N Fun 2012:

Blue Skies, Belite Ultralight Airplane

Severe Climb Angle? with Belite Ultralight Airplane

Wednesday, March 28, 2012

Weight of WoW ultralight airplane

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Day 2 at Sun N Fun:

Flying, showing instruments, talking to people, enjoying the weather.

Belite Ultralight Aircraft climbing out at Sun N Fun, Day 2

From the start of the takeoff, I could get to 300' altitude before the water tower turn.  With a 28HP engine.  Lots of people watching...   WoW.

Here's the estimated weight breakdown on the WoW plane:


1 Basic Airplane.   224.5
2 Carbon Fiber spar upgrade saves weight. -9.0
3 Metal Priming 0.9
4 Light Steel fuselage swap -3.5
5 Steel spring gear upgrade 2.2
6 Add electric start, wiring system, battery, battery box to base engine 6.5
7 Swap in Full Belite Instrumentation 0.0
8 Install Fuel Sender in fuel tank, wiring 0.6
9 550 pound Air Rocket Parachute - installed 17.0
10 Lightweight Lift Strut Swap - 2024 T3 -3.5
11 Upgraded Aluminum Fuel Tank 2.2
12 Complete Fuselage Fabric & Complete Paint 9.0




Subtotal 246.9




Other Options



1 Tip Lights 2.2
2 Spinner 0.8
3 Streamlined Lift Struts 6.0
4 Built Panel Bulkhead 2.2
5 Rear Fuselage Treatment 2.2
6 Heavy Elevator 3.0
7 Adjustable Elevator Trim 1.7
8 Adjustable Rudder Trim 0.6
9 Dots 2.0
10 Hydraulic Tip Brakes 2.0
11 Hoerner Tips 3.5




Total 273.1







I am so impressed with what this airplane's advancements has done for our aerodynamic performance.  WoW!

Belite ultralight airplane in cruise flight at Sun N Fun 2012














Tuesday, March 27, 2012

I flew the WoW plane today

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More from Sun N Fun, 2012.  Gene took lots of great photos of the WoW plane from Belite while I was flying it today.  Very nice photos, all posted on Flickr.

Here's some of the really good pics:

Belite ultralight airplane rotating into climb

On Short Final, officials watching

Flarint to a nice landing

Rolling Out

Here's some photos of the details on the plane:

Hydraulic Toe Brakes

Instrument Panel in Belite aircraft

News conference in the morning....  More tomorrow.

Monday, March 26, 2012

Fact Sheet on the WOW ultralight aircraft


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Ultralight Aircraft, WOW style, from Belite
High Res Photos of the WoW plane on our Flickr site.

Fact Sheet on the WoW ultralight airplane from Belite – in no particular order:

  1. NAME.  We call it the WoW plane because of the amazing paint scheme and the amazing combination of features it has.
  2. AMAZING PAINT SCHEME.  The aircraft is painted in Insignia White from Stewart Systems, with multi-colored dots of various sizes floating off the airframe.  I came up with the idea of floating dots.  If you think it looks like a bread wrapper, well… hmm.
  3. BASE AIRCRAFT KIT.  This ultralight aircraft is an example of many different ideas, all built into one Belite Aircraft.  Any skilled aircraft builder could make this airplane, starting with our base kit. 
  4. KIT PRICE.  Our base kit is priced at $7000, including a discount of $2000 at Sun N Fun, after show discount.  That includes just about everything required to build an ultralight airplane, firewall back.  (Regular price, non-show, $9000.)
  5. CARBON FIBER SPARS.  This ultralight aircraft has carbon fiber spars.   They are a $2200 option.  They save about 9 pounds and add considerable strength.
  6. HYDRAULIC BRAKES.  The aircraft has been fitted with hydraulic tip brakes.  From Grove Aircraft.  The tip brake design is ‘one-off’ (not documented in our build manual), but builders are encouraged to innovate and copy what we have done.
Hydraulic Toe Brake in Belite Ultralight Aircraft
  1. COWLING.  The cowl is constructed from fiberglass, and is optional in our kits.  The plane flies fine without a cowl.  It also flies fine with a cowl.  The cowl weighs less than 3 pounds.  We do not include it in our flying weight, because it is removable for flight. (BTW, the pictures don't show the cowl attached.  We just got it fitted on today, and we'll have more pictures tomorrow.)
  2. AIRCRAFT WEIGHT.  The plane weighs about 275 pounds, including parachute.  The legal maximum weight for an ultralight aircraft with parachute is 278 pounds.
  3. ENGINE.  The engine on this plane is a Hirth F33, producing 28HP.  It weighs about 47 pounds, including the muffler.  It uses premix oil/fuel, at a 90 to 1 ratio.
  4. PROPELLER.  The propeller is a 58 x 22 wooden propeller from Tennessee Propellers.  It is very lightweight and sturdy.
  5. FUSELAGE.  The fuselage is constructed from our 4130 chromaloy steel.  However, this same airplane could have been constructed from our aluminum fuselage option.
  6. MORE ON THE FUSELAGE SHAPE.  The rear fuselage and the bottom fuselage was ‘built up’ with a series of angle aluminum longerons to add cross section shape, then covered with fabric.  You can see the internal aluminum structure by looking inside the fuselage, from the cockpit.  This helps make the airplane look like any other ‘real’ airplane.
WoW Ultralight Aircraft from Belite, viewed from underneath.  Note wingtip detail (Hoerner style), note nav lights; also note underneath fuselage shape detail and elevator trim tab detail.
  1. STRUT FAIRINGS.  Notice that the struts are faired, providing a streamlined strut structure.  Very nice.
  2. LANDING GEAR ‘A’ ARMS.  These are also faired and covered with fabric.  So is the cross bar, under the fuselage, connecting the landing gear together.
  3. SPRING LANDING GEAR.  The main landing gear use steel springs, replacing bungees.  They make hard landings soft and also make taxiing a lot more comfortable. 
  4. INSTRUMENT PANEL.  The panel is made from ultralight weight Belite Electronics instruments and and the entire panel runs off of a single 9 volt battery.  Battery life is about 8 hours.  Current usage for the entire panel is about 55 milli-amps.  The panel could also run off any power source (including ship power) between 9 and 14 volts.  If you look at the plane, you can see the battery velcroed behind the panel.  The panel is completely removable by removing the wing nuts on the four corners.  The missing instrument is the airspeed indicator --- oops!  Sorry!  I frequently fly without instruments so it’s not a big deal to me.   The entire panel weighs about 12 ounces.  We do not include it in aircraft weight because it is removable and not required for flight.  I cut the panel aluminum on our ShopBot.  We can make nice panels in just a few minutes, from CAD on the computer to finished product.  Very cool.  Here's a pic of a similar panel, on display:
Instruments from Belite Electronics, for experimental and ultralight usage
  1. PANEL STRUCTURE.  In the WoW airplane, notice that the instrument panel is connected to a classic aluminum structure, built from bent aluminum sheet metal and faired around the cross bracing under the windshield.  Very nicely done.
  2. WING DESIGN.  All of Belite’s aircraft utilize an expanded span and chord (25’ 2” span; 40” chord).  As a result, Belite’s wing produces more lift at slow speeds, which makes it ideal for ultralight operation.  (But the wing in the WoW plane has even greater span, due to the Hoerner wingtips… see below.)
  3. FLAPERON DESIGN.  All of Belite’s aircraft utilize an expanded flaperon, with a 12” chord.
  4. HOERNER WINGTIPS.  This aircraft was built with a one-off Hoerner wingtip design.  This increases span and reduces tip vortices in flight, causing better lift and reduced drag.  In other words, better performance low & slow. A while back, I wrote a nice explanatory post on Hoerner wingtips.
Hoerner Wingtip on Belite Ultralight Airplane

  1. HORIZONTAL STABILIZER / ELEVATOR.  These control surfaces are built with an aerodynamic cross-section.  This gives better control and smoother flight characteristics, due to drag reduction.  The stabilizer has a 2024 T3 spar; the elevator spar is built from Chromalloy steel. 
  2. RUDDER TAB.  Note the ground adjustable rudder tab.  Very nicely done.  This is another ‘one-off’ feature which I would encourage our customers to copy.
  3. ELEVATOR TAB.  Note the inflight adjustable manual elevator tab.  The control lever is to the left of the pilot’s sight.   It runs to the rear of the airplane using a single Bowden cable.
  4. FLAPERON CABLES.  The flaperon cables are very low friction.  In flight, the aircraft feels like the control surfaces are on ball bearings.
  5. TAIL WHEEL SPRING.  Constructed from spring steel, we have them made for us by a local spring vendor.
  6. POSITION / NAVIGATION LIGHTS.  We’ve equipped this ultralight airplane with position lights.  This allows ultralight flight for 30 minutes after sunset.  
  7. ‘Y’ CNC MACHINED LIFT STRUT FITTINGS.  There are several machined parts which we make at Belite, on this airplane; the strut lift fittings at the base of the fuselage are a great example.  They are hogged out of solid aluminum.
  8. LIFT STRUTS.  The lift struts are constructed from 2024T3 aluminum, 1.00 x 0.035 wall, on this airplane.  This is a builder option.   It is lighter than 6061T6 aluminum.  (The lift struts are covered with the plastic extruded fairings.)
  9. FOR SALE?  Hmm.  Good question.  This was built to be our demonstrator and also to be James’ personal ultralight airplane.

Sunday, March 25, 2012

Wow Plane

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It's time for Sun N Fun.

We had very little fun preparing for Sun N Fun -- it was Rain N Pain in Wichita for four days, and our field was flooded.  The gang was working nearly non stop, working on preparing 3 planes.  One was a customer delivery, and it had highest priority.  Another was a show plane, which we did not finish in time.  The third was a technology demonstrator, which we call the Wow Plane and it also would be going to Sun N Fun.  Mike had been working hard on the Wow Plane for several months, and the rest of our gang was working on finishing it up.

The rain ended Thursday night, and a walk of the flight field on Friday morning showed a diagonal path across the runway which avoided puddles and headed into the wind.  We had to fly the Wow plane!

So we rolled out the Wow Plane.  Around 4 in the afternoon, it took to the air for the first time.

Wow.

Wow!

Phenomonal crisp climb with only 28HP.  Flight controls as if they were on ball bearing rails.  Lots more.

And you'll find out lots more, soon, in a news release from Belite Aircraft.

The Wow ultralight airplane from Belite aircraft
You can see more pictures of this cool plane immediately on Belite's flickr account.

Thursday, March 8, 2012

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.

Tuesday, March 6, 2012

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


Monday, March 5, 2012

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. 21st 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.

Saturday, March 3, 2012

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

Monday, February 20, 2012

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.
  

Sunday, February 12, 2012

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.

Wednesday, February 8, 2012

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.


Tuesday, January 24, 2012

How to laminate carbon fiber to plywood

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!


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.


Monday, January 16, 2012

Mile High

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!


This morning, I'd had no hope for flying today.  I called the airport weather line, and it reported that the wind was gusting to 26mph.  In a crosswind, making takeoffs and landings insanely impossible.

Come along with me, I have a story to tell.

I had wanted to fly this plane today:

Yellow Ultralight Aircraft from Belite

So, I went about my work in the shop, and felt badly that I couldn't fly due to the crosswinds.

Afternoon crept around, and another phone call to Jabara weather showed a much more favorable wind:  crosswinds had reduced to 15mph.  Improvement, for sure, but still well above my limit of 7mph crosswind.

Another hour later, and the winds were down to to 8mph.  With the ability of our huge grass runway to angle into the wind, either on takeoff or landing, I was now safe to fly.

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The gas tank was not full, but I didn't care.  I wasn't planning to fly for more than a few minutes.  I wanted to check out some engine mounts that I'd been experimenting with -- which type would produce the smoothest engine, in conjunction with the new, amazing propeller we'd been trying out?

Last week, I'd tried the new propeller/engine combination for the first time.  On another aircraft, it had produced some fairly eye opening takeoff and climb performance, as documented in this video:  (Click on the picture, and go for a ride!)

Belite Ultralight Aircraft takeoff video
(Click on the CAPTION, and the video will load and play....)

Today, I was trying the same propeller/engine combination on the yellow aircraft, along with some slightly different engine mounts.

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I'm off the ground easily and quickly, and the altimeter has passed 3000 feet in the climb.   (Ground level is 1400, so I'm plus +1600 over the ground...)  I'm kind of amazed that I'm not cold.  I have just my winter leather coat on, a hat, and some good gloves.  Normally, for winter flying, I wear coveralls.  But not today.

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And now the altimeter has reached 4000 feet above sea level.  The views are beginning to be a bit surreal:  Jabara airport is now a long ways below me to the west; I can see Hawker Beech field to the south, and Benton (Stearman Airport) is just 4 miles to the west.

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Still climbing; the altimeter passes through 5000 feet.  I no longer am doing anything other than having a good time.  For some reason, the idea of climbing is just a lot of fun.

====

The views are very, very good.  I am able to take off my gloves, and retrieve my phone from my pocket, and take some pictures:

Hawker Beech field to the south (left of center in this photo)

Jabara airport to my right

Looking towards the southeast

I keep considering the feel of the engine.  It sounds strong.  I make a note of the squawks to be corrected before customer delivery of the airplane, later this week:

  a)  the control stick is a little right of center in straight flight -- adjust rod end bearing setting to fix
  b)  (maddening)  the EGT/CHT is inop -- must fix!!!
  c)  midrange roughness in engine -- adjust belt tension to ensure no slippage and adjust carburetor mixture
  d)  the floorboard is made from beautiful stained wood (hey, we've always done it that way) but I've decided to change this airplane (and all future airplanes) to aluminum, for safety sake.  The muffler is below the engine and ahead of the floorboard, so putting in a floorboard firewall seems like a good safety idea.  We have some 2024 clad aluminum for this application.
  e)  the brake cable on the left side is skewed.  It needs fixing.
  f)  the radio still does not have the antenna installed, and needs to be tested thereafter.

I think I'm forgetting one squawk, but I wrote them all down and gave them to Gene after the flight.  

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While the ground winds were 6 knots when I took off, I can tell that the winds aloft at my altitude are very fierce, yet very smooth.  I am pointed into the wind, yet I am hovering in place over my home field.  My ground speed slows to literally 10 knots.  (With a slight bit of work, I could have moved backwards.)  (And this is really no big deal.  I've done this kind of thing before in other aircraft.  I remember hovering over a wheat field many years ago, in a Cessna Cardinal.)

====

The altimeter has reached 5,200 feet ASL.  Just about one mile above sea level.  While I'm nowhere near the maximum ceiling of the aircraft, I'm running out of time, gasoline, and warmth.

I've been higher in a Belite before, but this flight was a little better documented.

Do you remember my old blog post,  What Altitude Did James Reach...?  I certainly flew higher that day.

Panel of Belite Ultralight Airplane at 5200 ASL!

Time to go down.

One more picture of me ---

James in Belite Ultralight Aircraft, really really high off the ground...
Really time to go down.

I push the nose over, and the airspeed indicator shows 70 mph.  (Redline is 80mph.)  I put in a couple of notches of flaps, and it helps reduce the fairly significant elevator forces, as the plane does not want to go down.  Of course, I work in some power reductions.

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And I land.  Back on the ground.  Gene comments on how I'd been a hovering spec in the sky.

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I've been recording the flight on GPS Essentials, on my DroidX phone:


The proof is in the flight profile.  Climb to 5200 feet; ground speeds below 10mph (and nearly 100mph); turning into the wind and with the wind.  Climbing at a steady rate of about 180fpm. 

(looks like someone made a move in Words with Friends)

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Thanks for sharing this flight with me.

James Wiebe, @jamespwiebe on twitter, please follow me
James is the EAA 2011 August Raspet recipient


Saturday, January 14, 2012

World Class Takeoff and Climb

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!


Our Belite ultralight aircraft is now demonstrating world class takeoff and climb performance.

This is our new aluminum airplane design.  The propeller / engine combination has been tweaked for optimum performance and smoothness.

We've got some great new video which proves it ---

You can see the video here.

(Thanks to friend Jim Loewen for providing the video.)

Make sure you are following James on twitter:  @jamespwiebe

-- James Wiebe, EAA 2011 August Raspet recipient

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.

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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