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Thread: Pressed Wing ribs

  1. #41
    skywagon8a's Avatar
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    Mike,
    The puckers become more of a problem when the radius of the bend gets smaller. Such as the nose of the rib. The excess materiel needs to be shrunk and is more easily done with -0 materiel. This is where the rubber comes in, holding and molding with the materiel while the press moves it down. The T-3 material tends to fold the excess which is not desirable. A long rib made of T-3 will tend to form in a long curve. In my view the mold would need to be made with a curve in it to compensate for the resistance to shrinking of the T-3.

    One method of making the mold for T-3 use would be to make some dimples in the mold. This wouldn't look good on a Cub rib having the dimples in the cap strip.
    N1PA

  2. #42
    www.SkupTech.com mike mcs repair's Avatar
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    Quote Originally Posted by skywagon8a View Post
    .

    One method of making the mold for T-3 use would be to make some dimples in the mold. This wouldn't look good on a Cub rib having the dimples in the cap strip.
    thats actually how Univairs STC'd ribs have been made...

  3. #43
    www.SkupTech.com mike mcs repair's Avatar
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    Quote Originally Posted by Lowrider View Post
    Very COOL!! Was the 100 ton press necessary to get good results?
    no, just happened to be what I found used... But, remember that's the force applied to one square inch only, so if you apply it to larger area it's much less collectively

  4. #44
    www.SkupTech.com mike mcs repair's Avatar
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    found another old article on rubber pad forming

    https://dl.dropboxusercontent.com/u/18944249/Rubber.pdf

  5. #45
    www.SkupTech.com mike mcs repair's Avatar
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    looks like some of that magazine are available for down load at https://archive.org/details/aerodigest

  6. #46
    www.SkupTech.com mike mcs repair's Avatar
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    added some more pics in "press forming" album http://picasaweb.google.com/mike.skup,

    made a few attempts at pa-12/J5 style aileron nose ribs, got them as nice as piper originals(see pic), not as nice as modern Univairs(smoothness), had to retemper?? edge from a original piece of .020" 2024-T3 to a -T4? state that temporally softens it??, and form it quickly, then after rubber forming, hammer to shrink excess...

    just experimenting.... still need to pour a urethane rubber pad that will fit in a metal box.... to do a true Guerin process -focus all the pressure at the die...

    want to make an outer die also like "Fat Cub" shows in the jigs and fixtures thread to try.. http://www.supercub.org/forum/showth...l=1#post493027

    ???? http://www.thefabricator.com/article...ation-for-6061

  7. #47
    Lowrider
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    Just a thought, I know it's an entirely different process but is there some way to use hydro forming techniques to smooth out the forming process? Maybe the urethane with some heavy oil to transfer the shape and to lube the material and let it flow easier? Just a thought.
    Somewhere along the way I have lost the ability to act politically correct. If you should find it, please feel free to keep it.

    There are no new ways to crash an airplane no matter how hard you may try!

  8. #48
    www.SkupTech.com mike mcs repair's Avatar
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    Quote Originally Posted by Lowrider View Post
    Just a thought, I know it's an entirely different process but is there some way to use hydro forming techniques to smooth out the forming process? Maybe the urethane with some heavy oil to transfer the shape and to lube the material and let it flow easier? Just a thought.
    thats the next fancier way that its done, with a hydraulic bladder above the rubber, more pressure/accuracy

  9. #49
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    Quote Originally Posted by 8856Charlie View Post
    Attachment 20126 Working on a carbon rib this one is 7 OZ! Just build new molds to try it a little different. But yes they can be done!

    Nice rib, did you complete a wing wing them? Please describe more of the process that worked for you. Any more pictures?

  10. #50

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    So I did eventually go with carbon ribs...
    All the full length and 3/4's made.
    They are super strong. Have not weighed them...
    All nose ribs complete.
    Will start assembly in the new year when I have some space cleared...
    Been busy fitting out the fuse..
    Click image for larger version. 

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  11. #51
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    Quote Originally Posted by STEEL View Post
    So I did eventually go with carbon ribs...
    All the full length and 3/4's made.
    They are super strong. Have not weighed them...
    All nose ribs complete.
    Will start assembly in the new year when I have some space cleared...
    Been busy fitting out the fuse..
    Click image for larger version. 

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    The rib looks excellent. How has you wing project progressed?
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  12. #52

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    Herewith some pics:
    Leading edges have been dry fitted, but final fixing not yet done.
    need to get the tanks in so I can finish the top straps...
    2nd wing is at almost the same stage as the first one now.
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

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  13. #53
    Dave Calkins's Avatar
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    absolutely fabulous!

  14. #54
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    The wing tip is amazing. Please post more photos and details when you have time!

  15. #55

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    To make the Wing tip shapes, I started with MDF shapes of the ribs at the end.
    Cut polysterene to the outline shape and glued them onto the MDF.
    Shaped the polysterene the the leading edge shape at the front and then slowly changed the shape to match the ribs as cut.
    First doing the rough removal and then sanding smooth.
    Doing left and right wing tips almost at the same time to get almost perfect symmetry.
    Then glass the polysterene with 6oz glass cloth and spray up to get a smooth finish.
    Wrap in carbon with peel ply and vacuum bag.
    Alot of work for only 1 left and 1 right wing tip, but I am happy with how they came out and prefer this look over the traditional wooden bow tips.
    Click image for larger version. 

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  16. #56
    Rob's Avatar
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    Awesome work. What are you using to bond the ribs to the spars? I always wonder what would take the flexing without trying to delaminate. Also did you ever get a chance to weigh up the ribs?
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  17. #57

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    Quote Originally Posted by STEEL View Post
    Herewith some pics:
    Leading edges have been dry fitted, but final fixing not yet done.
    need to get the tanks in so I can finish the top straps...
    2nd wing is at almost the same stage as the first one now.
    For some reason, I can't see the pics. It says "Attached Thumbnails" but no images. I'm very interested in your composite ribs. Are you able to repost the images? A few other questions: 1) How many layers/weight CF? 2) Epoxy hand brushed, resin infusion, pre-preg? 3) Is it layed up over a male rib plug or a female mold? Thanks! Awesome work!

  18. #58
    www.SkupTech.com mike mcs repair's Avatar
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    I can see images


    Sent from my iPhone using SuperCub.Org

  19. #59

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    Quote Originally Posted by mike mcs repair View Post
    I can see images
    Sent from my iPhone using SuperCub.Org
    Thanks for the update Mike. I tried using an Edge browser and it works fine. In Chrome it works for some images but not others. Works on my iPhone using Chrome.

  20. #60

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    Quote Originally Posted by aecub View Post
    For some reason, I can't see the pics. It says "Attached Thumbnails" but no images. I'm very interested in your composite ribs. Are you able to repost the images? A few other questions: 1) How many layers/weight CF? 2) Epoxy hand brushed, resin infusion, pre-preg? 3) Is it layed up over a male rib plug or a female mold? Thanks! Awesome work!
    I used 2 layers 6oz cloth then a 3mm composite core with the cutouts and then another 2 layers of 6oz cloth.
    i would wet out each layer of cloth on a piece of melamine before placing over a polished male mold.
    Then peel ply, and vacuum bag all together. Got good results over all the ribs.
    I have a couple left after my wing build so will weigh one and let you know what weights they came out at.
    the 3mm core is the part that gives the rib the extra strength as it has some shaped cutouts etc so it’s not just flat shape.
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  21. #61

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    That's some really impressive work. I'll bet those ribs are insanely stiff.

  22. #62

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    Steel, you may find this other carbon fiber cubalike of some interest: https://backcountrypilot.org/communi...rototype-13841 unfortunately this project has been abandoned I understand..

  23. #63

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    Quote Originally Posted by courierguy View Post
    Steel, you may find this other carbon fiber cubalike of some interest: https://backcountrypilot.org/communi...rototype-13841 unfortunately this project has been abandoned I understand..
    I was going to bring up that was back in 2013. Unless I have not seen otherwise it has not gotten into other hands and been finished.

  24. #64

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    Yeah, it's dead as a door nail, I just thought he would find it interesting if he was not aware of it. All smoke and mirrors to me, composite work frightens me, I sure like the end results though.

  25. #65

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    Composites can be nice to build but to do it right there are allot of tooling and consumables to make a part right. The old fashion hand layup or the layup over foam the way Rutan's designs were built look easy going in but the second effort work to finish the surface makes the part just as time consuming as building a mold in the first place while you end up with heavy parts. I am actually at this decision point in my own build.

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