Phantom V2 - DLG - design build

[bracesport]

I have joined the three bottom sections of each wing half and have trimmed the curves into the foils to make the basic wing shape from the template - next I will sand the LE back into the foil where I made the trim cuts.

 

[bracesport]

Some more bits - the boom section I am using is currently 50cm long and tapers from 22mm to 12mm - I made it over a pool cue mandrel - CF braided sleeve over some unidirectional fibers - weight is 16g.

 

[bracesport]

My next job is the shear web - I have laminated 8 strips of the 80g 90/0 CF weave to make a 1mm thick strip - the first process will be to glue the shear webs into the foam wing panels - the second step will be to sand in the top and bottom rebates to glue in the 3x1 CF flats - I did consider a stressed wing construction but I decided on the shear web spar and will lay the cloth skins at 45 deg with a 90/0 doubler strip over the spar and TE.

I am also gluing the butt joins of the three wire cut wing panels with 3M77.

 

[bracesport]

The shear webs are cut and the epoxy is curing - tomorrow I will put the caps on - the process will be to sand in a 3x1mm flat recess then epoxy the caps into place - I may do one side first depending on how fiddly the process is.

 

[bracesport]

This is my little 3x1 sanding tool.

 

[bracesport]

So the big news of the day is I am going back to dihedral (6 deg per side) for this build - my mates convinced me to keep it simple - ditch the extra servos - get the weight down - print a new wing saddle mould - live the easy life!

 

[jonoashton]

fantastic work... as usual !

 

[bracesport]

It is the stop start epoxy work that slows you down!

fantastic work... as usual !

 

[bracesport]

Well here goes nothing - I cut the top slots and epoxied the caps into place - I have the epoxy curing for an hour or so with the mylar in place - then I will check if there are any voids and top up the epoxy for the final cure - a lot of work for these little buggers!

 

[FoamyDM]

you are doing such a thorough job documenting this process. It is much appreciated

 

[bracesport]

It is so I can remember what to do next time!

you are doing such a thorough job documenting this process. It is much appreciated

 

[bracesport]

Now for the other side - all the practice yesterday made it all a bit easier today - I also changed the sanding grit to 80 and the slots were done in a breeze - the top side has glued well, but I suspect the bottom will be better!

 

[bracesport]

Knocked off a few small jobs while the wings are curing - I put the first coat of PVA on the fuse moulds - recycled my throwing peg - de-glued the wing servos - good thing about 5min epoxy it peels off - I am getting excited about next weeks jobs.

The V1wing is fully decommissioned - it is a nice foil but you can see the heavy skins - it was just too heavy for a DLG.

 

[jonoashton]

You could use the old wing by cutting it in half, making a centre panel (perhaps 1m) and useing the old wing as wing tips. Perhaps would end up with a wing of about 2.5m for an electric thermal model ??
Jono

 

[jonoashton]

Or just use it on windy days. That might be easier

 

[bracesport]

That would have been a good idea but I put the bandsaw through it!

Or just use it on windy days. That might be easier

 

[bracesport]

The spar is in and the wing is very stiff - the current weight of the panels is 70g - sadly I did not weigh them before adding the spars, but I am reasonably happy so far.

 

[bracesport]

Today I bagged the bottom surfaces which includes the kevlar hinge tape - I have never bagged two sides at once and I was not comfortable to start doing that today! I used my silver film (not exactly sure what it is made of) against the FG and then added the mylar - this means I don't need to worry about waxing the mylar's as the epoxy does not stick to the foil.

 

[bracesport]

Success on the bottom side overnight - some 'small' imperfections on the the edge of the kevlar tape in one section of one panel but otherwise not too bad - 50g cloth 45/45 deg with CF tip reinforcement - I added CF pigment to the epoxy which has given me a smokey 'camo' look and feel - I was hoping for a darker tint, but its all good so far - Ill get the top side done this morning and then leave them to harden for a few days.

 

[bracesport]

The top surfaces are in the bags - the FG cloth is wet out on the foils and also on the foam has a light coat - once done they are laid up together and the mylar is taped on top - each wing has its own bag - both bags are vacuumed and then set in there foam blocks with an extra 30kgs on top.