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Thread: And so it begins

  1. #121

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    No skill, just hours of YouTube University study and a phone consultation with Ted Waltman.
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  2. #122

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    Finished the cargo area floor. The hole is an access panel for elevator cable pulleys. It now has a CF cover plate. On the list for interior CF is the under seat storage bin, fuel selector cover plate, cargo and cockpit door sill cover, pulley covers and maybe the instrument panel. Rear seat back and bottom and the front seat bottom is already CF.
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  3. #123
    RVBottomly's Avatar
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    Quote Originally Posted by Mr. Ed View Post
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    Finished the cargo area floor. The hole is an access panel for elevator cable pulleys. It now has a CF cover plate. On the list for interior CF is the under seat storage bin, fuel selector cover plate, cargo and cockpit door sill cover, pulley covers and maybe the instrument panel. Rear seat back and bottom and the front seat bottom is already CF.
    That is astounding. I'm over here marking out plywood.

    I've done quite a bit of fiberglass/composite work on boats, but carbon fiber just seemed one step too far. Maybe I'll rethink that.

  4. #124

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    Still working on the carbon fiber floor. I made carbon fiber 3/4”x3/4” angle, 13’ of it, cut it into smaller pieces and bonded those to the floor sections using West Systems Six-10 epoxy. The sidewall panels were trimmed to final fit and screw holes were match drilled to the carbon fiber angles. I used Click Bond floating 8-32 nut plates bonded to the angles. You can see those being bonded in one of the photos (pink rubber clamping piece sticking out).

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  5. #125

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    I tried my first three dimensional carbon fiber piece. It snaps over the cargo door sill and covers the rudder cable and a pulley below the door. Fabric will wrap over the sill so I put 8 layers of masking tape down to simulate the thickness of the fabric. The CF is five layers which results in 1/16” total thickness and quite stiff. There’s a CF angle bonded to the floor that will have a couple Click Bond nut plates in it to secure the sill cover to.
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  6. #126

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    Pulled the under seat storage box off the mold today. Didn’t turn out great but it’s acceptable. I used 2” pink foam board to make the mold. Under vacuum the ends of the foam board compressed a little so the left and right sides are a little wavy. Four layers of CF resulted in the box weighing 1.678 pounds.

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  7. #127

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    panel layout......just stickers at this point but components are being ordered. Dynon 10” HDX, radio & intercom, AV-30, Avidyne 410 GPS navigator. Switches will be located on the angled section on the bottom of the panel. CB’s are electronic through Advanced Panel’s ACM.
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  8. #128

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    made a carbon fiber flange that bonds to the floor around the aft control stick. Snaps are pop riveted to the lip, a leather boot was stitched to fit and snaps into place. Hopefully it will keep everything you drop from making it into the belly.
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  9. #129

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    New toys came via UPS. So I built a new instrument panel out of carbon fiber and fiberglass. The bottom of the panel that angles out at 45* was too narrow for the switch panels on the aluminum one I built. Where things will fit isn’t optimal but tubing behind the panel drives location. Center screen is a Dynon HDX 10”. Left of the HDX from top down are radio, intercom and autopilot. Right of the HDX is an Avidyne GPS navigator and AV-30E. The hole cover is where the amphibious gear switch goes. Ignition switch upper right. Still have a few small holes to cut/drill. No CB’s because I’m using Advanced Panels ACM.
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  10. #130

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    Most of the summer did not include working on the cub although I did work on some small parts. I spent three weeks up in AK working on the cabin we are building. Off grid, on an island, access only by boat, grueling work. Fished a couple days and pulled some nice shrimp close to the island.

    Back to the project now. Running wires, crimping pins, drilling mounting holes, bonding nut plates & trying to wedge 5 gallons of stuff into a two gallon space. Click image for larger version. 

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  11. #131
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    sweet build! did you decide to go with the traditional floor mounted flap, or overhead flaps? After flying both, I think the overhead flap is a very important mod that I would want. It's WAY more functional than reaching down on the floor. I don't quite follow the objections about it being something you would bang your head on in a crash - everything in the cub is 4130 steel and will take your head off in a crash. That overhead flap handle will keep your head up so your eyes can see out. Only way to go in my book if you have the option.

    Jay at Javron will build fuselages with the overhead flap - I'm sure you can get parts from him for the flap handle. Since you ordered your wings from him - ask him about it.

  12. #132

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    Got all the big stuff mounted today. Still a couple small things to go. Screwing around with small stuff like nut plates and making things fit right is a huge time suck. 30 nut plates plus tweaking and trimming ate 6.5 hours today.

    Yes, I have the overhead flap handle. I bought the handle that Jay (Javron) makes.

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