Psyborgs Edge 540 build log

PsyBorg

Wake up! Time to fly!
Well i am finally getting back to semi sane life and found a little bit of motivation.

I asked Igoo57 to print up the plans and got them in my grubby paws last Friday.

Now that I am a few steps into it I will start posting progress.

First step was to align and tape the tiles together. This was SUPER easy thanks to how Sponz layed out the plans with all the alignment marks.

Igoo57 also handed me a bag of magnets to hold the tiles in place. Since I do not have a metal plate or table the refrigerator mafe a nice stand in.

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Next I spent two days cutting out the pieces and gluing them to poster board.

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Once all that was done it was back to cutting them all out again. This is now where I am at with it and will begin cutting foam as I go and need each piece.

Here are all the templates layed out in sections.

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The first stage is done with the inner frame complete. Here are the pieces cut and ready to be assembled.

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And here they are as a completed section.

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Here are the two lower fuselage shins cut and ready to form before adding them to the inner assembly.

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As final progress for the afternoon here are those two parts and how well they formed. The detail and accuracy of these plans are amazing if you are like me and enjoy building from scratch with just the printed plans and a build video.

Andres did an incredible job with this and that makes it that much more enjoyable to build.
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PsyBorg

Wake up! Time to fly!
Welcome to round two. I forgot to get a pic withbthe pattern and the cut foam but here is that tail section put together


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Here is the tail section glued to the rest of the fuselage. Its actually straigh AND square. My edges where it mates to the rest of the fuselage are not perfect but thats cosmetic issue for later should it survive long enogh to get pretty.

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Here is where I stopped last night. The turtledeck is cut and will be the first piece added today.

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Here is the turtle deck installed.
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So far this build has been as easy as any other FT build be it scratch or speed build. We really dont give the designers or Sponz enough credit for what they do.

Next comes the tail feathers. I am a little nervous as these are single layer foam but I will go with the flow and see how well it holds up.

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Seems I was even able to build it and have everything square :eek:

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Here is where the skill level get raised from easy to near insane. I cut this piece three times because the level of detail and acvuracy needed is higher then expected.

The kerf of the fine point sharpie I used to trace out the pattern and mark the folds even effected how squared up and well formed this piece is.

I would suggest they sell this particular piece as a laser cut replacement on its own so more people could have success with this build.
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The fianal attempt here took my blind shaky handed self close to four hours on this and its still not as perfect as I would like. But it pretty much maxed my abilities to get this far.

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Here are the upper fuselage parts all cut out.

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Here is the parts all together. Again the pen kerf added up and bit me. The front is slightly wider then the lower just behind the cowl.

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The cockpit went together preety eadily with only minor beveling needed to close the seams better.

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Here is the completed fuselage. You can see the slight difference in width at the cowl where the uppr fuse lage meet.

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Now on to the main wing. The parts are cut and the assembly was staight forward. I lile this design better the some of the other FT wings I have built.

To me I will probably use this style on anything else I build.

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I found when test fitting that there is a slight twist in the fuse and some minor shimming will need to be done. I posted that question at the current end to confirm before making any thing permanent.
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PsyBorg

Wake up! Time to fly!
Welcome to the final round. After a few nights of fitting and shaping and sanding I have managed to get the main wing in line with the elevator.

I could still do some more fine sanding and get gaps less obvious but I dont care on this one. If I manage to get it in the air and flying I will save up and get a kit over winter to do and make pretty while I bash this one about learning to do what I want it to.

The camera is hard to get everything lined up to show it is square and the way I was holding it did twist the front a touch supporting all the weight by the cowl.

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Anyway here are the pretty pics of the complete air frame together.

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The only thing left to do now is cut the aileron hinges, add control linkages and horns. Then I just have to set end points. I will add the side force generators after I have a few flights under my belt as well as try out landing gear.

All up weight with the flight pack is 843g, and is 685.5g without. All the servos are centered. 100%, 65%, and 40% rates are set on all three channels with 55% expo as well.

Maiden will be with a 2200 mah 3s pack using a 10x4.5 prop. Waiting now for the rain to stop and things to dry up before I do a proper glide test. Hopefully someone will be around to make a crappy cellphone video for me.
 
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JimCR120

Got Lobstah?
Site Moderator
Ooh this looks like it'll be a colorful build which should make orientation easy. Planning on lights?
 

PsyBorg

Wake up! Time to fly!
I am hoping it will be an air frame by the weekend.

@JimCR120 its colored poster board I got from the dollar stores clearence sale at the end of last years session. The plane will be standard ft wrf brown until I am sure it AND mysrlf can safely fly it. Then it will get full colors.
 

PsyBorg

Wake up! Time to fly!
That is the plan for the day.

Cutting all those lines neatly and straight is MUCH harder now though as my granny glasses broke at the part of the frame that holds the lenses together so they are now a two piece....

Seems I cant escape Bills Law even when sittin on me duff exerting mini.al effort.
 

rockyboy

Skill Collector
Mentor
That is the plan for the day.

Cutting all those lines neatly and straight is MUCH harder now though as my granny glasses broke at the part of the frame that holds the lenses together so they are now a two piece....

Seems I cant escape Bills Law even when sittin on me duff exerting mini.al effort.

If you have a pin drill and plastic frames, I've had good luck with this repair method

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PsyBorg

Wake up! Time to fly!
Gonna try the hot glue and bamboo skewer trick once I dig my glue gun from the remaining FFO pile o thingz.

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PsyBorg

Wake up! Time to fly!
OR.... I could just wait til I go grocery shopping and get a new pair hehe.

Anyway more progress was made. Will edit first post with the update.