Help! Circle plane foam moulding

leo370

Member

Hello! I am currently working on designing a plane similar to the XF5U (flapjack plane), and I need help with foam moulding techniques to so that I can have the entire circle be an airfoil shape, but all of the edges touch each other. I am using standard sheets of dollar tree foam board. The plane will have 2 motors, a bomb drop mechanism, and have a wingspan/length of 1.2m. Will give more info as needed.​

 

quorneng

Master member
leo370
A double curvature structure is never going to be easy if built using flat and relatively stiff boards.
Sometimes you have to use a construction technique appropriate for the desired end product.
For example with 3D printing you can create almost any shape!

The classic solution to building a double curvature structure using a flat material is by using "planking" like boat builders do.
It can be used for planes but it is fiddly, time consuming and takes some practice to do neatly.
 

Piotrsko

Legendary member
If you have a lathe or a rotary table mill with a swing that is bigger than your wing span it's easy (kinda). could attach it to a plywood board attached to a spindle and swing it by hand but those methods only work for sculpting foam in a symmetrical circle. The flapjack had a modified Clark Y with incremental changes for each rib station to make it circular. At least on the demo board at Ames KEDW
 

leo370

Member
These are pictures of the build!

IMG_1390.jpeg


I decided to use twin rudders and differential thrust to hopefully gain yaw stability, since there is no fuselage.

IMG_1411.jpeg


The airfoil is a simple Flite Test style airfoil.

IMG_1416.jpeg

The plane will fly on a 4s 3300mah lipo battery, I hope that I can fly it on 2 of them with one for each motor.

IMG_1424.jpeg


My original idea was to have a bomb bay in the middle similar to the tubby b-17, I unfortunately do not have the skills or patience to make one. I might add a drop mechanism straight on the bottom at some point. My landing gear are 2 wheels from an aeroscout, a tail skid, and some 3mm wire to hold the wheels on.
 

Piotrsko

Legendary member
Hope that blunt surface mid wing isn't finished yet. However, don't see much reason it wont fly, my 36" pizza pan slow flier worked really super
 

leo370

Member
Hope that blunt surface mid wing isn't finished yet. However, don't see much reason it wont fly, my 36" pizza pan slow flier worked really super
I have covered the whole thing now, just working on landing gear and hatches. Is there a fractional amount back from the leading edge that your plane balances? Thanks!
 

Piotrsko

Legendary member
Typical flat bottom sheet metal spun pizza pan: 25% of chord but horiz stab was huge for the wing area maybe 25% with another 10% for elevator.
 

L Edge

Legendary member
I built and flew a 3 ft geobat and the 2 things I remember:

1) plane rolls very slow so you might have to fly like a trainer. That is, use a lot of elevon and plenty of rudder to make a sharp turn. Mine had only 1 engine, you might include differential thrust with the two motors as well as rudders.
2) Get some time in before you you try winds, especially gusty. Ended up making a spoiler to trim nose to get correct AOA depending on wind speed.

Hope you take video and post.
 

Piotrsko

Legendary member
What's its weight?

Looking at it, @L Edge seems correct, going to roll slowly or you did a super job building the tail feathers/ or are using elevons
 

leo370

Member
What's its weight?

Looking at it, @L Edge seems correct, going to roll slowly or you did a super job building the tail feathers/ or are using elevons
The plane weighs 3lbs 5oz with 1 battery. Most likely it will roll slow, I have added differential thrust so that should help.
 

L Edge

Legendary member
One additional point, if plane acts wonky, might be the "P" factor, so try c/cw props so flow across each half of dome is the same.
 

leo370

Member
She flew!

IMG_1512.jpg


The plane was very sensitive in pitch and yaw, but very sluggish in roll. On the first flight it was tail heavy with a single 4s 3300mah battery, so I added a second one. It flew great after that. The video is the 3rd flight on it, after I had fixed the C/G.

IMG_1513.jpg


Here is the link!

Thanks for all of y'alls help with this!
 

L Edge

Legendary member
She flew!

View attachment 256640

The plane was very sensitive in pitch and yaw, but very sluggish in roll. On the first flight it was tail heavy with a single 4s 3300mah battery, so I added a second one. It flew great after that. The video is the 3rd flight on it, after I had fixed the C/G.

View attachment 256641

Here is the link!

Thanks for all of y'alls help with this!
Well done. See you like to explore different shapes from your other vids. That's the fun of this sport.
 

Mr NCT

VP of SPAM killing
Moderator
She flew!

View attachment 256640

The plane was very sensitive in pitch and yaw, but very sluggish in roll. On the first flight it was tail heavy with a single 4s 3300mah battery, so I added a second one. It flew great after that. The video is the 3rd flight on it, after I had fixed the C/G.

View attachment 256641

Here is the link!

Thanks for all of y'alls help with this!
👋👋 Congrats! Powering a new one up and letting it go the first time is always a rush.