Archive for Control System

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

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Sculpting Top of Slave Strut

TopOfStrutBeforeWeld

Sculpting Top of Slave Strut

TopOfStrutWelded2

Top of Slave Strut Welded

TopOfStrutWelded

Top of Slave Strut Welded

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The Doldrums…

Posted in Cowling, Super Stinker X with tags , , , , , , , , , , , on August 1, 2013 by mars58

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IMAG0467So, I am knee deep into the details. Building sub components were one thing and “Aircraft Assembly” is daunting at times. Thankfully, just like everything else, getting my private pilots license, competing in the IAC, heck building this plane, the deeper you get, the more you learn and more importantly (the most fun part), the more you do, the easier it gets.

Most of July and August, I have been practically memorizing Aircraft Assembly, putting together order lists down to the nut, washer and bolt, finalizing the last bits and pieces to get the complete control system hooked up and working. We also started fitting the cowl and completing the upper ailerons.

I have met with our local DAR, Joe Gauthier, who will be inspecting and ultimately giving me my airworthiness certificate. He has helped me to start thinking about the mountain of paperwork that I am going to need to satisfy the FAA.

And on Two high notes I have ordered my Prop, thanks to Whirl Wind Aviation and should be receiving my Sky Dynamics light weight sump, intake as well as the 6 into 1 exhaust soon.

Looking Like an Pitts

Posted in Bottom Wing, Empennage, Fuselage, Super Stinker X, Top Wing with tags , , , , , , , , , , , on July 1, 2013 by mars58

You have to forgive me, the words are overcome by excitement. Since this project started I have been holstering my excitement knowing just how long of a haul it was going to be. But looking at her standing on her own for the first time, power plant in place, tail, wings, etc. I am left kinda speechless. We still have a long way to go; electronics, firewall forward, covering and paint, etc. But I can’t help to take a breath and enjoy this stage for a few seconds. I hope you enjoy the pics as much.

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Finishing Up Elevator Controls System

Posted in Empennage, Super Stinker X with tags , , , , , , , on October 20, 2012 by mars58

With the majority of the plumbing done it was time to finish up the control system to the elevators. This took a great attention to detail to make sure everything was level, even and square before we tacked in the control horns to the elevators. With that said we have a total travel of 40 degrees up and 40 degrees down.

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Lower Wings are Skinned!

Posted in Bottom Wing, Leading Edges, Super Stinker X with tags , , , on December 21, 2011 by mars58

We finished up installing the lower wing leading edges, wing tips, hinges and bell cranks. As Dave pointed out, it is nice installing stuff for the final time. Next step is the aileron coves and these babies will be ready for cover.

I apologize for not having any pictures, I did take them but my POC Motorola Droid 3 wont let me retrieve the pics. Ugh I hate Motorola and phone contracts. Pics to come.

Drag Wires and Control System

Posted in Bottom Wing, Super Stinker X, Top Wing with tags , , , , on February 22, 2010 by mars58

Friday night I went over to Wayne’s and took the final measurements for the Drag and Anti Drag wires. Here is a good picture of the wires in a wing. This is from one of my friends builds.

A Drag Wire Bay

So I went up to Yard Metals in Bristol and picked up the 416 HD harden steel rods. I got 18, 4 foot long segments. Dave created a nice chuck for the tailstock of the lathe that replaced the quill and held the die.

A Good Diagram of a Lathe

The rod slid into the head stock and was held by the spindle and chuck. Then all I had to do is engage the lathe and push the tailstock with the die onto the stainless steel rod and wait for it to hit the mark. Then reverse the lathe and voila screw threads.

Rod in the Lathe

Marking The Thread Length

Cutting Threads for Drag Wires

Drag Wires

Dave picked up the final laser cut parts Friday, so while I was cutting threads Dave was welding the idlers.

Welding Control Idler

Welding Control Idler

Welding Control Idler

Control Idler

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