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Working out issues with brackets

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Posted (edited)

Trying to help a friend.....has led to a long and expensive project for both of us. Nearing completion of a rock solid set of dies to make parts....lots to plan ahead for here. Next up is a die set for aluminum ribs. 1000 bar of pressure using rubber press pad over solid positive die. Will require compression struts or extra ribs....more testing on that later. Looking into lighter, stronger wings without carbon spars. this will save a lot of rib associated problems and flaperon issues over time. The "sticks" in the pink foam are my tungstens for the tig machine...keeps sharp ones handy. Last but not least...some of my welding porn.

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Edited by Tree top pilot
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Posted (edited)

Very Interesting Project,

     One of the guys (SkyPirate) made ribs out of aluminum sheet by hand with some aluminum and wooden dies he had made - I got to see them, the dies, and one of the wings he had made with them for his daughter's ultralight - probably 1/10th or 1/20th  ( :huh:)  the weight of our wood ribs - Looked really good.

     Are these parts going to be for sale?

EdMO

Edited by Ed In Missouri

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Posted

Wowser, great project! And one I'm interested in because for the life of me I can't find one of the spar attach reinforcement brackets I made years ago for my A+. As for the aluminum ribs, I'm all for it. We got to move these new builds into the 21st century whenever possible and I can't think of one other modification that would better do that and solve so many issues as stamped aluminum ribs. I would buy them in a heartbeat and make new wings for my A+ project, maybe sell a 'wing kit' that includes ribs with new strut attach and spar attach brackets so the spar material can be sourced separately. I assume you're referring to the Avid Heavy Hauler airfoil, right? Might consider the Riblett airfoil used on the KF4 and up, or the Aerotrek A220/240 airfoil, both offer much better cruise with little to no S.T.O.L. penalty. I can get you an intact aluminum main and nose rib for the later if interested, also pics to show how they addressed the flaperon hanger issue on the both the wing and flaperon sides. Much superior to Avid and KF design, IMHO. Good job, rock on and keep us updated!

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Posted

In the works as time and funds allow. Working with another engineer on FEA testing on flight loads and other scenarios that it will have to endure. Then when the 1rst one is built it will be loaded until it breaks something. Right now it looks like 15 ribs and no compression struts per wing. The ply ribs are too much work to make and heavy when sealed. We have found in a search "Kitplanes for Africa". Downloaded the PDF build manual and really like the spar reinforcement. Simple yet effective. Now there is when carbon fiber will excel layered with another material to withstand compressive loads. I just can't get the numbers with carbon spars to settle enough to trust them...too many variables. Still teetering on an extruded "I" beam spar. Still retaining the fold option as well. One thing is that titanium has fallen in price. That's another good weight saver. Took out my control stick{steel} and replaced with titanium .040 wall. lost 5 ozs in that alone. Grandfather always said- take care of the pennies and the dollars will mind themselves....wish I knew then what I know now. So as my work and health hold out...we will plunder onward with all these endless projects. Simple things like moving the attach point out on the spars help a lot....even 8 inches. Compressive loads go up but the wing seems to accept gust loading easier....in the computer. We are still looking at every piece of info we can to cherry pick areas for improvement. Already a pile of metal to the recyclers. Lots of tests.

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Posted

Just a reminder - Kitfox moved the strut attach point 10 inches farther out in the later models.

EdMO

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Posted

Did this project ever go anywhere?

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