Lower Wing Aileron Coves

Posted in Bottom Wing, Super Stinker X with tags , , , , , , on October 17, 2014 by mars58

I’ve been working on the lower wing aileron coves. I decided to go with wood coves instead of aluminum. It’s been a lot of detail work sanding out the correct radius and getting the correct clearances that will allow for paint and covering. Here are a few pics. The first is the drawing for the aluminum coves. Main takeaway is the 2.38 radius and the 1.77 height of the top and bottom of the cove.

Cove and Aileron Dimensions

Cove and Aileron Dimensions

LowerleftWingBottomBare

LowerleftWingBottomCoveEdge

LowerleftWingBottomCoveEdge-1

LowerleftWingBottom

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Control System, Final Details

Posted in Ailerons, control system, Super Stinker X with tags , , , , , , on July 18, 2014 by mars58

Sorry for lack of action on the blog, here is some catch up from May…

The last part of the control system has been the Slave Struts. The S-1-11 has Four ailerons. The stick is moved left and right, pushing and pulling tubes, through idlers and bell cranks in the lower wings which move the lower ailerons. The lower ailerons have arms that come off of the front of the aileron spars that connect to the Slave Struts which connect to the top wing’s ailerons via, you guessed it, arms that come off the front of the top aileron spars. So when the lower ailerons move they move the upper ailerons. One critical part of this besides lining it all up correctly was to get the slave struts lined up behind the I struts.

The slave struts start life as a piece of streamlined tubing, round tube and some flat steel. At the bottom of the strut is a Rod End bearing. The streamlined tubing is notched to allow the smaller tubing to be welded into it then threaded to receive the rod end. The streamlined tubing is then cut at an angle on the front and back for clearance. This will bolt to the lower aileron arm.

At the top of the strut is a fork. The flat steel is bent into a fork, a U shape that is welded to the top of the streamlined tubing. The fork is what the bearing in the top aileron arm will fit between. A bolt will go through the fork and bearing connecting them. Before welding the fork I used a dremel and sanding drums to sculpt the top of the streamline tubing, meticulous and tedious but it allowed me to get the strut exactly where I wanted it.

Once the struts were welded I finally had a complete control system. The next step was to expand the clearance around the struts and aileron hinges by removing bits of the aileron skin until I had good clearance.

Lower end of Slave Strut

Lower end of Slave Strut

Lower End of Slave Strut

Lower End of Slave Strut

Lower End of Slave Strut

Lower End of Slave Strut

Lower End of Slave Strut

Lower End of Slave Strut

SlaveStrutAndLowerAileron

Bottom of Slave Strut Connected to Lower Aileron

TopOfStrutBeforeWeldRearView

Sculpting Top of Slave Strut

TopOfStrutBeforeWeld2_101642

Sculpting Top of Slave Strut

TopOfStrutBeforeWeld

Sculpting Top of Slave Strut

TopOfStrutWelded2

Top of Slave Strut Welded

TopOfStrutWelded

Top of Slave Strut Welded

Holidays and BMW

Posted in Distracted with tags , , , , , on January 20, 2014 by mars58

It’s been a little while. Since Christmas I have been chasing a problem on the Bimmer.

Driving home the day after Christmas, the Service Engine light came on. She got us home but died in the driveway. Luckily she started right up and I put her int the garage. Last couple of miles there was a persistent whistle. End up tracking it down to a blocked crank case breather, which requires a valve cover replacement. In the mean time I changed the water pump, thermostat, camshaft sensor, cleaned VANOS solenoids, replaced a leaking oil filter mounting plate gasket and took 106,000 miles of road dirt off of her. Luckily I haven’t had any major problems up to this point. I have attached some pics.

Almost Two years ago I started noticing a greasy build up around the inside of the oil filler cap. I don’t know what causes this, I’m guessing too long oil change intervals. I won’t be following the BMW recommended interval any more. 5k miles at most for me now. The crank case breather is integrated into the valve cover. You can see why this was a problem.

Electric Water Pump and Thermostat

Tight area to work in.

Tight area to work in.

Engine Before the Valve Cover Replacement

Engine Before the Valve Cover Replacement

Just Popped the Valve Cover

Just Popped the Valve Cover

Cams All Gunked Up With Sludge

Cams All Gunked Up With Sludge

More Sludge

More Sludge

VANOS All Gunked Up With Sludge

VANOS All Gunked Up With Sludge

Sludge Around VANOS

Sludge Around VANOS

Sludge Around the Exhaust VANOS

Sludge Around the Exhaust VANOS

Cleaned Up The Sludge

Cleaned Up The Sludge

More Clean Up

More Clean Up

Cleaned Up Sludge, Luckily it Dissolves With Oil

Cleaned Up Sludge, Luckily it Dissolves With Oil

Sludge Inside of the Valve Cover

Sludge Inside of the Valve Cover

Sludge Inside the Valve Cover

Sludge Inside the Valve Cover

New Valve Cover Installed

Brake Assembly and Wheel Pants

Posted in Grove Brakes, Super Stinker X, Wheel Pants with tags , , , , , on December 2, 2013 by mars58

Been spending some time assembling the brakes and fitting the left wheel pant. Took me a little while to get the assembly all worked out and now it’s a matter of getting the wheel pant aligned properly aesthetically and aerodynamically.

Very Excited to Join the Whirl Wind Aviation Family

Posted in Cowling, Fuselage, Super Stinker X, Whirl Wind Aviation with tags , , , , , , , , on November 17, 2013 by mars58

I want to thank Tonya and everyone at Whirl Wind Aviation for my beautiful prop. Great people to work with and very sexy looking prop. I can’t wait to fly it. And it looks great on the 1-11.

Pictures don’t do it justice, but here are a few.
IMAG0653

IMAG0654

IMAG0655

IMAG0657

IMAG0658

IMAG0659

IMAG0660

IMAG0661

IMAG0662

IMAG0665

IMAG0666

IMAG0667

IMAG0668

IMAG0649

This Is Going to Be A Cool Weekend

Posted in Super Stinker X on November 15, 2013 by mars58

Just saying, stay tuned.

Here is a hint… 🙂
IMAG0635

IMAG0636

IMAG0650

IMAG0651

Bit by Bit

Posted in Ailerons, Cowling, Cowling, Super Stinker X, Top Wing with tags , , , , , , , , , on November 12, 2013 by mars58

Last post I had just installed the aluminum piano hinges that hold the Two cowling halves together. Not Two days later Dave gives me a call and says he found a guy that makes carbon fiber piano hinges, Carbinge. So last week I was able to swap out the aluminum hinges and install the new carbon ones. I have a few pics below. This weekend I cut and notched the top ailerons and was able too get them hung. It was nice to see all the major components coming together. The top ailerons really complete the picture.

Top Ailerons Installed

Top Ailerons Installed

Top Ailerons Installed

Top Ailerons Installed

Top Ailerons Installed

Top Ailerons Installed

Top Ailerons Installed

Top Ailerons Installed

Top Ailerons Installed

Top Ailerons Installed

Top Ailerons Installed

Top Ailerons Installed

Top Ailerons Installed

Top Ailerons Installed

Top Ailerons Installed

Top Ailerons Installed

Top Ailerons Installed

Top Ailerons Installed

Carbinge, Carbon Fiber Piano Hinge Lower Cowling

Carbinge, Carbon Fiber Piano Hinge Lower Cowling

Carbinge, Carbon Fiber Piano Hinge Lower Cowling

Carbinge, Carbon Fiber Piano Hinge Lower Cowling

Carbinge, Carbon Fiber Piano Hinge above Aluminum Hinge

Carbinge, Carbon Fiber Piano Hinge above Aluminum Hinge

Carbinge, Carbon Fiber Piano Hinge above Aluminum Hinge

Carbinge, Carbon Fiber Piano Hinge above Aluminum Hinge

Carbinge, Carbon Fiber Piano Hinge above Aluminum Hinge

Carbinge, Carbon Fiber Piano Hinge above Aluminum Hinge

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