Crunched Cornell Rebuild Begins

Waaaay back when, on June 1, 2011, I crashed my beautiful Cornell. While looking for parts and a possible replacement plane I discovered that Eflite had just discontinued it...

She was a beautiful flyer, a good looking airplane. I had just gotten comfortable with her. I flew her, did some aerobatics, and while pulling through a loop I started a bit too low to begin with, I eased up on the elevator to open up the loop, and she slammed into the ground. Pure newbie badness.

Greg Reed took her to repair, but he just couldn't get to it. Today he returned it to me, now that I have some experience fixing planes. So, I started today!

Greg was having problems with his CA and epoxy holding, so the wing, which was broken clean off (you can't tell in the crash pic, but under the cote it was cracked clean off) remained separated. I took some time removing the glues and cutting the wood surfaces clean.

When I broke her, I broke her good. I noticed I am missing the hatch that goes on top... Wonder if Greg has it? This will be the most industrious rebuild to date. The wing is sheared off, and the firewall/motor mount is toothpicks. I have to see how much of the motor mount I can rebuild. I am considering using an Electrifly replacement motor mount.

I have fabricated a new leading edge and rejoined the wing. It looks pretty flush and level. 

I rebuilt the framework using salvaged wood and popsicle stick set with CA, fixed in place with epoxy. I didn't have a big enough piece of balsa for the leading edge, so I made one with scrap wood laid over a dowel, then sanded flush forming a ply. Worked quite well. Pretty much the entire right side of the frame is refabricated. Need to level out a few spots with scrap sanded to fit, otherwise looks pretty good and strong. The square is a thin piece of sheet balsa covering and strengthening the cracked and depressed sheet balsa of the wing root. Letting all of this congeal, will sand the excess epoxy and framework so things are flush, then recote the wing. I don't think its added much weight at all.

In the next several days I will tackle the motor mount and firewall which were shattered in the crash. I also plan to upgrade the servos, some of which are toasted.

Hanger 9 Twin Otter... Yeah, baby...

This is totally my next big plane. I have always loved the DeHavilland Twin Otter, and Hanger 9 has a winner with this one!  Its available at Horizon Hobby in the USAF livery of the UV-18B.


Twin Otter ARF

Key Features

• Painted fiberglass Engine Nacelles, Cowlings, Nose and Main Gear Fairings
• Fixed Landing Gear with functional Oleo Nose Strut
• EVO 36/Power 25 ready
• Low-speed handling improved and stall speed reduced by Clark Y airfoil
• Easy-going sport plane flying manners
• Exceptional scale outline
• Plug-in wings with slotted flaps installed
• Balsa/light plywood airframe
• All hardware included
• Easy and fun landings made possible by large landing flaps

Overview

Hangar 9’s Twin Otter is a scale model of the UV-18 'Twin Otter' is the military version of the DeHavilland DHC-6. The trim scheme is based on the three UV-18B planes used by the US Air Force Academy cadet parachuting program which carry a pilot, copilot and up to 17 jumpers, and are the only three owned by the Air Force. Although this is a multi-engine model, the high wing design and Clark Y airfoil improve low speed handling and provide stable flight characteristics which make this a great first-time twin for intermediate to advanced pilots. The Twin Otter ARF also features an electric power option which adds to the reliability and fiberglass cowlings and fairings which make it very durable and easy to repair. The aircraft also includes fixed gear and large landing flaps to provide easy and fun landings without the addition of complicated landing gear being necessary.

The full scale version!

Stearman Before and After

Three weeks ago...

Today!

Stearman Rebuild Complete

It was three weeks ago I stalled and crashed my beloved Eflite Stearman. A lot of work and waiting, and today, I installed the cowl, the prop, and tested her motor and surfaces. Everything in working order! I checked CG and its spot on.

But as I have learned with this hobby, "its always something".

Last night I poured some extra epoxy into the front of the cowl to strengthen the brown part. I left a wadded up paper towel in the hole to keep it from leaking all over, not anticipating it would soak into the paper towel and, well, wad up the hole... I was able to cut and dig this out easily.

I was able to clean it up pretty well.

The cowl is on. Its a tight fit, getting the motor centered to clear the cowl. I also hand drilled 4 holes in the front face of cowl to increase air flow through the motor and across the ESC. Otherwise the only way air gets into the fuse is around the prop hole.

CG is spot on! Can't wait to fly!!!!

Nose Job

A blink away from completing the repairs to my Stearman. I set up the mount screws per the instructions (geez, I took no pics...). Using card tabs placed over the mount posts, I note the location of the mount holes and transfer them using a Sharpie to the cowl, then drill the holes in the cowl. Honest though, just like the Eflite instructions. I added a post to the top of the cowl to hold the weight of the lead in the cowl a bit better, though it was doing pretty well before. I have to be careful where the lead goes or the motor or ESC blocks the cowl. There's a lot of weight. I am using the same amount of weight, in fact the same weights, as were in before. I used 60 minute epoxy, let it set overnight and put the cowl on tomorrow. I put some of the weight on the motor block, where a piece was already. That's it, ready to fly Friday.

New post at the top of the firewall.

I also set some, well, a lot, of epoxy in the front of the cowl that is the false motor cylinder set. Its very fragile and this epoxy will strengthen it. The false motor is beautiful, the best one I have seen on a Stearman, but the plastic is extremely fragile. The "wires" on the front snap off if moved at all.

Can't wait to fly!

Stearman almost ready!

Repairs on my Stearman are nearly complete after her stall crash. I detailed the major repairs in a previous post. The cowl, cabane struts and N struts arrived from Horizon today. I had found I needed to replace only one of the N struts (the other is bent a little but fine otherwise), and used one I had to replace the other. I installed the cabane struts fairly simply, some minor annoyances from screws not quite lining up on one of the forward struts attachments to the fuse post repair.

I had to repair the lower carbon fiber wing support spar since it fractured and they are out of stock at Horizon. In re-installing the wings it gave me issues, overcome with some sandpaper and a light layer of strong cursing. In the end everything lined up nicely and fits straight. I did find I had to remove a couple of the fiberglass tubes through which the CF spar passed, one in the fuse and one in one of the upper wings as they were damaged. Tested her control surfaces and everything is sweet.

She looks great! I will install the cowl tomorrow and replace the nose weights, reset her CG which has surely changed with the repairs. I am so looking forward to having her ready to fly this by this Friday!

Alpha rises

I described the crash and rebuild of my Eflite Alpha 450 Sport in "Asleep at the switch". Yesterday the PowerUp 450 motor arrived from HeadsUpRC (fast shippers, those HeadsUp guys). I installed it last night, with some minor difficulty getting the standoffs in place and getting a good thrust vector on the motor due to changes in the firewall from the repairs. She fired up sweet! the prop adapter that came with the motor was too small for the APC 10x6 I am flying on her, so I had to drop by my LHS today and pick up an Eflite one. It is a tad short so I can't use the stock white spinner...I'll have to see if I can find a longer 4mm adapter.  It looks a little naked without it.

The nav lights had issues. I plan a short blog entry on those later. A couple of them stopped working and it took some time to trouble shoot that it was the bulbs. I ended up sacrificing the other kit I ordered for a couple of its bulbs, but for now everything looks good. The forward facing white light is quite bright so I may get the scale landing light effect I was going for; the light may not wash out in sunlight. We'll see! So, Alpha is ready, and come Friday when I can get away to the field, weather permitting, Luke and I will return to the sky!