Electric Edge 540 build log #10

I have been debating on whether or not to try and drill past the carbon strips for the vertical fin post or not. The problem is that the carbon strips do not go all the way thru the fuse so the drill bit is likely going to wonder off the side and the resulting hole will not be vertical. I went slowly with a slightly larger bit than needed hoping the bits stiffness would help keep it from wondering. The rear post hole is good! The front post did slip off the side of the carbon but I am satisfied with the front post being just into the balsa. 

Really the last thing to work on until the covering order arrives is the cockpit.  I am looking for a picture to print and use as the pilot. The obvious is a picture of me but that has been done over and over along with snoopy… I wish I could find a higher res shot of Kirby Chambliss from the wing mounted gopro like this one. Anyone know Kirby?

Electric Edge 540 build log #9

What is the first thing you always do after building a wing? Slide the plane together and make it look like a plane!! Here is the Electric Edge 540 coming together.

The only actual building today was trying to decide if the vertical fin posts are deep enough into the fuse without trying to drill thru the carbon. On the Warbirds, the post went all the way thru the fuse and helped lock the stab in place as well.  I am going to have to sleep on it….

Electric Edge 540 build log #8

Time to birth a wing! Having cut literally hundreds of F2D leading edges and lots of 1/2a wings I thought I would just bang out a couple quick wings and move on… Na let’s make a day of it! 

I marked a large foam block for 4 wing panels and set up my very highly engineered jig for cutting the blocks. 

Hooked up the transformer to the bow and ………… nothing. I guess my transformer gave out while sitting on the shelf waiting for use? So dug out the older one and got to making foam fumes. 

Next I marked the center line to mount the templates with my handy dandy center of the foam marker tool and installed templates with torturous looking nails.

Panels cut, templates mounted, - now for the airfoils - Boing! After about ¾ of the first airfoil cut the wire broke and I managed to test the heat with a couple of fingers as the wire squirmed around making intermittent contact. OK no big deal just make another wire and get back to work, after running 3 minutes of cold water on the fingers just for fun.

 Wire broke about riiiight ----here!

Found these cool clamps in the “clamp drawer” from 1/2a making days. Pat Willcox turned me on to these in early 2000. With these clamps and some white Gorilla Glue wing is joined in 20 minutes.

On all the Warbirds I built in 2010 I used 1/2"x1/8" spruce spars. 

Being that we are in 2018 I thought I would go a little more modern and use .063 fiberglass rods for spars instead. They are less than half the weight and should “flex” when hit from the top and not break like wood spars.  Should.  

I set up the Dremel with a .054 bit because I do not have a .063 bit... and cut a very straight slot thanks to the aluminum guide. 

And just like that the day is shot… Tomorrow I will get the wing and spars trimmed up and weighed. Then likely cut some lightening holes to reduce the weight and add some bi directional fiber tape from the tape drawer.

Electric Edge 540 build log #7

I sorted the hardware for the bell crank mount today. I will run a slip in wing that can be replaced if damaged so putting the bell crank in the wing is not an option. I cut a piece of aluminum angle to 1” and trim it up. Bell crank bolts to that then glue/bolt the aluminum to the fuse from the outside. I am going to wait to install the mount until the fuse is covered. On the Warbird I ran connectors bolted direct to the bell crank and ran the flying lines right to it. On Edge 540 I am going to run Spectra flying lines and do not want to take a chance with them rubbing thru on the lead out guide so I will run typical steel lead out wires off the bell crank.

Edge will have a trick carbon fiber bell crank too

Warbird set up - flew it today 15-25 mph winds with Spectra lines

Warbird set up 

Warbird set up 

Electric Edge 540 build log #6

I got the plug for the plastic canopy remade out of plywood to keep it from collapsing under the pressure when shrinking the plastic. I also realized that when I sanded the turtle deck down to take off some weight that the old plug was the wrong shape anyway. The process is really easy, get the thinnest water bottle you can find, cut the ends off put the plug in it, go crazy with the heat gun and trim. So 4^th time is a charm…

Electric Edge 540 build log #5

For combat durability is a pretty high consideration. The planes I built for the War Bird Series in 2010 are still going strong and get heavy intermittent use as lawn darts for my friends and family. These planes took a play from Lee Liddle’s playbook with Coroplast tail feathers and it turns out the stuff cuts great on the laser leaving a super clean edge. I like to put a carbon tube in close the hinge line to act as a spar. (Black arrow) Even better is the elevators can be hinged by simply removing the “skin” on one side between the vertical ribs on the bottom of the hinge line leaving the top skin as the hinge. (Red arrow) Couple each side with a piece of 1/16” music wire and you are ready for heavy prop on tail action. (Blue arrow) These tails will stand up to all kinds of heavy hangar rash also!  

That is some legit prop chopp'en toughness!

The motor mount worked out better than I thought it might when I started. We will see how it stands up to combat soon enough.

Here is where the project is now. I thought I had foam for the wing – I do not. I thought I had enough covering – I do not. Both are on order and with the holiday may take a few extra days to arrive. There are a few little items to check off like the bell crank mount/pushrod/control horn and canopy but then I will have to wait on the shipments to arrive.

Electric Edge 540 build log #4

Being a profile plane I was not familiar with how to mount an out runner motor but I needed a set up that would let me change motor sizes if needed. I chose an L bracket mount (AKA the corner of an electrical rough in box from the hardware store) that will bolt on to the outboard of the fuse.  I also got the aluminum “L” bracket cut to shape for the bell crank mount.  More on that later…

Still concerned about weight I wanted to remove as much material as I could from the fuse. I had already removed the canopy area with the laser so I took out the razor plane and went to town on the turtle deck and the belly. Have I mentioned that I DO NOT like to plane and  I DO NOT SAND!! Combat planes are not expected to live long enough for these sadistic type of actions... The 2.0 version will get the swiss cheese treatment in the laser and that will be that! 

Next I routed a slot with the Dremel tool and laid in a couple strips of pultruded carbon for some good ‘ol combat strength. Clamping curves is always a fun exercise.

Electric Edge 540 build log #3

After Howard Williams advised me that weight was going to be an issue I began thinking about saving weight where ever I could – A clear plastic canopy should save a few grams and look trick too.

Electric Edge 540 build log #2

I think this is how I will proceed with the electronics placement -  

The Electric Edge 540 build log #1

There are not too many electric combat planes floating around. So I thought it would be fun to come up with an "E" plane for the 2019 Air to Air Combat series. To help incentivize development there will be a bonus for flying electric models in the series.

The first details are what equipment will get a plane to 75 mph and be powerful enough to maintain that speed through repetitive combat type maneuvers for 4 solid minutes? Most of the info online suggests that .25 IC engines are about 450-650 watts. Bob Mears has run an electric plane in Tuscon for the last several years and says that 2800mAh is the minimum capacity that is needed for the batteries. There are many factors that influence these combinations so there should be more than one acceptable set up.

I am going to start with a 700w 2836 size motor that is 2200kv. I am going to feed it a 1550mAh 6 cell battery. I know that above 2800mAh was mentioned as the min but I already have the 1550 6S packs. So instead of making unknown equipment purchases I am going with what I have in the shop for now. I also have a Castle Creations 75A ESC that may be over kill but will work for the maiden flight.

The after an educational conversation with Howard Williams of Warbird Series 1 fame, the weight of the electric equipment is the challenge to overcome. So I am going with a 450sq foam wing that will be removable from the fuse for later updates if needed. The fuse and tail section will follow the general moments and sizing of a Ringmaster. I found a 3 view drawing on the www and adapted it to fit the sizes needed. Next step is to decide on the motor mount.

Air to Air Combat is coming in 2019!

In 2019 I will host several speed limit events geared at low key combat fun. In addition to well known fields I am working with clubs in and around Texas that have never had a CL combat event of any type.  

The first event is getting put together for Dec 29, 2018 at Scobee field in West Houston. 

These are family friendly low pressure events so check out the rules below and get your equipment ready for the opening event! 

Air to Air Combat

This event is intended as a grass roots speed limit control line combat event with scale type models that encourages all skill levels to participate.

Specific Details:

1.  Any plane may be used - the model’s total weight must be less than 48 ounces.

 

2. Any engine up to .40 cubic inch may be used with any type fuel system and fuel. No in air adjustable systems or devices.

3. Line length is 60’ +- 6”, and the diameter 0.18". Handles must have a safety strap that attaches to the pilots wrist. All connections must be covered to prevent hanging up on your opponent’s lines.

4.  Speed Limit is 75mph = 7.3 seconds for 2 laps with a full streamer.

5. Streamers and leader string should be of equal length for all competitors. The length and material is at the discretion of the organizer; 10’ string and 10’ bio-degradable flagging tape is a good suggestion. Note that plastic flagging tape is a bad choice.

6. Random draws for all rounds with no repeat parings until all possible parings have been exhausted. All the points from each round will be added together to get the final score.  Optional eliminations- after the points rounds the top four flyers will be matched 1 and 4, 2 and 3. The loser of each match will fly again for 3^rd and 4^th, the winners fly for 1^st and 2^nd.

7. Matches are 4 minutes. The judges will give a signal to start the engines and the 4 minutes will begin at that time. After both planes are up and approx. 180 degrees apart the judges will signal the start of combat. At the end of the 4min the judges will signal to stop.

Match Scoring:

1.  Each pilot will earn 1 point for each second their model is airborne during the 4 minutes of the match.

2. Streamer cuts will be 100pts each. Cutting the string will count as a cut only if there is streamer attached to it.

3.  If both pilots complete the match without a midair collision that causes a crash, line entanglement that causes a crash, or flyaway, both pilots will receive a 200 pt. bonus. If one plane hits the ground independently of the other or lands and the other is still flying, only the pilot not involved with the ground will get the 200 point bonus.

4.  Realism Points:  Each model that is flown in a match will be judged for realism based on the general outline as well as the paint color, scheme and markings. These points will be added to the match score of each match flown. Once judged, that model carries those points forward, even if damaged during the event.

5. Electric powered models will receive 100 points to begin each match plus realism score.

Realism Scoring:

1.         0 points for typical unlimited combat aircraft.

2.         40 points for typical unlimited combat aircraft with color and scale markings.

3.         100 points for non-scale profile type aircraft, i.e. Flight Streak, Ringmaster, etc.

4.         125 points for scale profile type aircraft that is identifiable as a specific full scale aircraft but no scale paint scheme.

5.         150 points for non-scale profile type aircraft, i.e. Flight Streak, Ringmaster, etc. with a scale paint scheme.

6.         175 points for scale profile or built up fuselage type aircraft that is identifiable as a specific full scale aircraft and realistic paint scheme.

7.         200 points for exceptional semi scale aircraft with realistic shapes and details.