a couple printed ideas

[Steve Melton]

Steve quick question. I replaced left flap recently and lost red nut and head buttons https://www.rvplasticparts.com/product-page/flap-bracket-fairing-set-with-hardware They are not listed on Amanda's website as a separate item. Any chance to get three of each for fairings complete look? Castle nuts are getting getting rusty and ask to be hidden. :)

Amanda will take care of this. Since she handles all the printing and shipping it's probably better to email her directly but I'll pass this along to her.

[Steve Melton]

this preheat duct is on it's third year and is in original condition. it has been tossed around and not been treated with care but holding up fine. easy to install and remove, secure, does not scratch paint.

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20181117_123956_zpssfwxxjkj.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20181117_124015_zpscd8rllls.jpg


fiberglass reinforced at the exit

http://i1249.photobucket.com/albums/hh519/semelton500/cap1_zps3y5kgeep.png

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN1186_zpsfkwl2nil.jpg


spring rods installed

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20170213_195331_zpscmcuwpxs.jpg

[Vlad]

Amanda will take care of this. Since she handles all the printing and shipping it's probably better to email her directly but I'll pass this along to her.

Received thank you very much Steve and Amanda!

[cguarino]

Has anyone made a 3D printed cooling shroud for a Pmag?

[Red Mtn flyer]

Look at McFarlane. They make this in 2 sizes:
https://www.mcfarlaneaviation.com/products/product/6ADH/

[Steve Melton]

Has anyone made a 3D printed cooling shroud for a Pmag?

it could be done if the material was Ultem. one needs a dedicated high temp printer to print Ultem. ABS cannot withstand the heat under the cowl, except for a battery tray or something flat like that.

[Steve Melton]

thinking about a wingtip trailing edge fence. hey, you are going to poke your eye out with that thing.

http://i1249.photobucket.com/albums/hh519/semelton500/cap1_zpsc1rzcali.png

http://i1249.photobucket.com/albums/hh519/semelton500/cap2_zpsiuwjcxnh.png

[Bill Boyd]

Starfleet Command approves of your idea. :)

That thing looks wicked.

[Steve Melton]

ready to install and saddle up. Scotty, give me warp power.

[David Paule]

For looks only or is it functional in some obscure way?

Dave

[Steve Melton]

Both sides fitted with wingtip fences. Initial speed run at 6500 ft indicated no significant speed gain at 21.5 HG, mid range power. there was a perceived improvement to stability. it's hard to quantify but it seemed the stability was improved, like it was on rails. maybe beneficial to IFR flight. testing still to come at 12,500 ft.

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20181216_190439_zpsmt7qqej1.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20181216_190458_zpsft8skq8f.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20181216_170226_zps8xcg4j9y.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20181216_161048_zps5ds9wo6i.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20181216_161024_zpsud6uv78j.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20181216_165935_zpscdjxlmtd.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20181216_163722_zpsdawsa3eh.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_19691231_192704_zpsg5q3m3hb.jpg

[Steve Melton]

testing at 4K ft, stall speed appears to be 2 kts lower. more float on flare at landing.

[Snowflake]

Any increase in aileron effectiveness just before or in a stall?
Any predictions how effective they would be on the older-style tips? :)

[Steve Melton]

Any increase in aileron effectiveness just before or in a stall?
Any predictions how effective they would be on the older-style tips? :)

the stall speed was lower but the stall seemed slightly more abrupt. no change to aileron effectiveness.

make sure your wingtip can take the loading. mine are solid across the trailing edge. I think I see some additional deflection across the top of the right hand side tip that was not there before, or maybe it's just my eyes. no cracks in the paint. our wingtips were not designed for this type of loading so be careful.

and if your plane has those tiny #4 stainless steel screws in the wingtips, forget about it. the strength of that attachment method is 40% of standard.

[Steve Melton]

need to be careful with this one.

http://i1249.photobucket.com/albums/hh519/semelton500/cap6_zps7pgmo6ay.png

http://i1249.photobucket.com/albums/hh519/semelton500/cap8_zpss7yj2wmc.png

http://i1249.photobucket.com/albums/hh519/semelton500/cap4_zpshiuof590.png

http://i1249.photobucket.com/albums/hh519/semelton500/cap3_zpsipddk12a.png

http://i1249.photobucket.com/albums/hh519/semelton500/cap7_zpsko39kt9f.png

[sirlegin]

I bet you could print a center console like the gentleman made out of wood shown on VAF the other day??

[Steve Melton]

I bet you could print a center console like the gentleman made out of wood shown on VAF the other day??

that could be done but it would be a long print and not as nice as the piece made of wood. thx for the idea.

[Paragon]

Steve,

Designing winglets that actually work to improve wing efficiency is one of the more challenging aero design problems in the airframe aero world.

Very easy to make winglets that actually increase drag compared to plain tips.

Even the experts with good CFD and good design tools end up doing numerous wind tunnel tests, testing several permutations about the base design, then picking whichever works best.

In my view, you need an airfoil cross-section, you need a taller, less swept winglet, and you need some understanding of how to undo the vorticity that is already present. Not an easy job.

Good luck. I would say, expect roughly design number 24 to work.

-Paragon
Cincinnati, OH

[rocketman1988]

Yep, there's definitely engineering involved, especially with winglets...

I think iteration 24 is a bit optimistic...42 is the correct answer...:D

[Steve Melton]

a nice fit

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0010_zpsqosv5pww.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0013_zpshfg9fkuq.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0015_zpsqcszpvow.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0023_zps0crrgfig.jpg

[DaveWelch]

Steve could we (RV12 guys) interest you in printing some carburetor floats?
Take a look at our forum if you haven?t already.
Happy New Year!

[Steve Melton]

Steve could we (RV12 guys) interest you in printing some carburetor floats?
Take a look at our forum if you haven?t already.
Happy New Year!

Nope. Amanda doesn't print anything that could be hazardous to your aircraft but thanks for the inquiry.

[Tram]

installed the rudder pedal extension with vibration damper to right hand side. my initial barefoot thoughts are that I feel the ridge created by the damper under my foot where the flat surface feels better on the left hand side. the vibration damper adds .25 inch of length so it also feels closer. I must be sensitive to my foot placement because I like it always to feel just right. my pedal length is .52 inch extension from the bar. my pedals are angled further aft of bar than most, everyone has a different leg to pedal geometry. anyway, the removed pedal extension looked good, no signs of wear, it was tight when removed even with the clamping fasteners removed, original condition, about 100 hrs of use. I reused the attaching hardware, also no signs of wear, original condition. I haven't flow with this yet. I'll report after 10 hrs or so.

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20180909_202513_zpswa6tfrrl.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20180909_202709_zpsioobqnnn.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20180909_204124_zpsenhhh9g7.jpg


Are you sharing any STL files for these extensions for those of us with our own printers?

Thanks

Jeff

[Steve Melton]

Amanda said she is not sharing the files but you can buy from her. Her costs are relatively low.

As far as the rudder pedal extensions go, they perform well, are light weight and are available in custom lengths for the best fit. I especially like the vibration damper version. The damper is holding up perfectly and reduces the high frequency vibration. They have a very nice feel. If the damper ever needs to be replaced, simply replace with new one in less than a minute. No glue is needed to keep the damper in place because of the orientation of the internal stop. In general, I don't think we pay enough attention to our feet for overall well being. That's were the rubber meets the road.

[sirlegin]

This may sound like a strange request but what about a piece that just effectively dampens the vibration for those long legged folks that don't need an extension?

[DrillBit]

That's were the rubber meets the road.

That's where the rudder meets the sky? :cool:

Just installed a pair of the rudder extensions in my RV-9A. Perfect fit, well-thought out design-for-install-ability. Thanks, Amanda & Steve!

Even though I'm something of an altitude-enhanced American (6'5" in my socks), I got the maximum 1" extensions. Keeping my huge feet off the brakes is my priority. I figured I can go old school and subtractively shorten them as needed.

[Tram]

Amanda said she is not sharing the files but you can buy from her. Her costs are relatively low.

Thanks for the reply.

Sounds like a new Fusion project. ;)

[hgerhardt]

Amanda said she is not sharing the files but you can buy from her.....

Sounds like a good excuse to get SolidWorks (free through EAA) and go make your own files...

[Steve Melton]

We consider a copy of one of our designs the highest form of flattery.

[Steve Melton]

This may sound like a strange request but what about a piece that just effectively dampens the vibration for those long legged folks that don't need an extension?

the shortest extension we offer is 0.4 inch. that is measured from the bar to the foot contact. the vibration damper adds .14 to this measurement to be 0.54 but the damper will flex to about half so the working dimension is .047 inch.

http://i1249.photobucket.com/albums/hh519/semelton500/cap2_zpscfzuhuio.png

http://i1249.photobucket.com/albums/hh519/semelton500/cap1_zpsmewe4izq.png

[Steve Melton]

That's where the rudder meets the sky? :cool:

Just installed a pair of the rudder extensions in my RV-9A. Perfect fit, well-thought out design-for-install-ability. Thanks, Amanda & Steve!

Even though I'm something of an altitude-enhanced American (6'5" in my socks), I got the maximum 1" extensions. Keeping my huge feet off the brakes is my priority. I figured I can go old school and subtractively shorten them as needed.

thx for the comment.

the rudder pedal extension is engineered to be light weight and are hollow inside with printed crisscross reinforcement. if you cut them, you will expose the internals. that may be OK but will reduce the strength and they will trap dirt. they are about half the weight of the metal version but provide increased contact area to minimize foot fatigue.

I recommend to use a piece of wood to and make a trail fit to determine the custom size before ordering. When your foot is happy, the whole body is happy.

[Steve Melton]

again, feels like it's on rails. I like the feel. plan to leave the wingtip fences on for awhile.

running at 150 - 152 kts TAS, MP=19.2, 2322 RPM and 5.7 GPH. tanks are topped off.

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0030_zps1r9undse.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0031_zpsygwozz58.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0034_zpskpnny9lv.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0044_zpsq7qn5yfx.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0048_zpsaummurls.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0054_zpsqnabaxzj.jpg


missed the 200 kt mark by 1, ground speed = 199 kts, 150 kTAS, engine is loafing @ 2200 RPM, MP=19.7
http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0042_zpsvcr4nhx9.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0095_zpslkrpf47i.jpg

Starfighter https://youtu.be/2WBG2rJZGW8

[Tram]

Sounds like a good excuse to get SolidWorks (free through EAA) and go make your own files...


Fusion 360 is free to hobbyists..

[DrillBit]

thx for the comment.

the rudder pedal extension is engineered to be light weight and are hollow inside with printed crisscross reinforcement. if you cut them, you will expose the internals. that may be OK but will reduce the strength and they will trap dirt. they are about half the weight of the metal version but provide increased contact area to minimize foot fatigue.

I recommend to use a piece of wood to and make a trail fit to determine the custom size before ordering. When your foot is happy, the whole body is happy.

Thanks for the warning. I can envision a number of ways to reinforce the cross-cross without too much of a weight of penalty, when and if it comes to that. Worst case, Amanda gets another order....s?all good.

[Steve Melton]

These printed plastic parts have been installed for well over a year. Fuel drain fairings have been installed for two years. They have never been removed except for the tie down fairings with are designed to be removed when needed. No paint except for a light coat of clear on the RV-14 hinge covers.

I didn't clean them to show as is.

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0057_zpsnyqqukgj.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0060_zpsfeqsejtr.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0061_zpskvfc1k2e.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0063_zpsdynrflrh.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0064_zpsbh5js4ys.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0066_zps5bf04pl0.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0070_zpsgvh5u04d.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0071_zps5kddtpot.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0073_zps6mbdxho1.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0079_zpsauziev10.jpg

[Steve Melton]

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0085_zpslhd3uqnn.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0086_zps5wqhec5g.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0087_zpsntlcn3dn.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0074_zpshyk1wrjs.jpg


I installed the bugblade to show condition but it is removed for winter ops. The picture is blurry but it is in original condition.
http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0081_zpskgxxsqco.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0096_zpsz4y0glmj.jpg

[dwranda]

I printed a defrost vent cover. I thought it would be cool to have something out of the ordinary. Now to print a couple more since I put in 3 fans. The letters are raised a little so should be visible when sitting in the plane. We'll see when I actually install them.
http://i64.tinypic.com/vmzzwm.jpg
http://i64.tinypic.com/b4ceus.jpg

[Steve Melton]

cooling vent covers are neat.

it was a nice day to fly. So far, I like the feel.

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190105_130301_zpsshdijoe0.jpg

[Snowflake]

Bogey at 10 o'clock! Did you get intercepted or is that just some schmutz on the canopy? :)

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190105_130301_zpsshdijoe0.jpg

[Steve Melton]

I never saw him because I was taking a picture.... :D

Really, it was just lint on the camera lens.

[Snowflake]

I never saw him because I was taking a picture.... :D
:D

How did you come up with the shape for that winglet? Was it just "TLAR" engineering, or was there some math involved?

[Steve Melton]

:D

How did you come up with the shape for that winglet? Was it just "TLAR" engineering, or was there some math involved?

reference http://naca.central.cranfield.ac.uk/reports/arc/rm/2796.pdf

[rocketman1988]

Got a chuckle out of that...

[Steve Melton]

I saw this at Oshkosh in metal with felt. I thought it might be a good application for ABS since it doesn't scratch paint and would not need the felt. The downside is if someone forgot to remove it before flight.

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20180724_180934_zpswxapz9mu.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20180724_180949_zpsgmghktil.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/cap1_zpspn5cmwix.png

http://i1249.photobucket.com/albums/hh519/semelton500/cap2_zpsawq8ypcp.png

[Scott Hersha]

Steve,
I like the looks of your aileron locks and think it would do a good job in this application, partly because there isn?t a large load on the aileron lock in that location - near the trailing edge - and because the aileron isn?t that big. The only ?gotcha? in making the part may be the vertical part of the control lock where it fits into the aileron/wingtip gap. Some of us have a fairly narrow gap. A thinner center area than what it looks like in your post might be needed and should still work fine because of the lack of substantial leverage in that location. I have similar looking locks on all three of my RV8 controls and would be happy to share what I?ve learned in use on 4 RV?s so far. If you need someone to test prototypes let me know.

[Vlad]

Great idea Steve! You might need some sort of padding because strong and gusty winds may "work it out" completely without a strap. Also it could back off a bit and scratch the wax. Make it red make it visible. :)

PS; not related but funny story. Once on a very cold and windy day I forgot to remove an aileron lock. I made them out of moving pads joined by plastic tie wraps. Before taxiing I checked the controls and noticed the lock. It took me one minute to get the lock off the aileron. Stick shaking, didn't even shut down or exited the cockpit. Relayed to a lineman he picked it up :)

https://i447.photobucket.com/albums/qq197/N666BK/Ice/burrowing%20out%20-%201%206.jpg (https://s447.photobucket.com/user/N666BK/media/Ice/burrowing%20out%20-%201%206.jpg.html)

[Steve Melton]

maybe an attachment location for a "remove before flight" ribbon?

http://i1249.photobucket.com/albums/hh519/semelton500/cap3_zpsolqu7apn.png

[Steve Melton]

Steve,
I like the looks of your aileron locks and think it would do a good job in this application, partly because there isn?t a large load on the aileron lock in that location - near the trailing edge - and because the aileron isn?t that big. The only ?gotcha? in making the part may be the vertical part of the control lock where it fits into the aileron/wingtip gap. Some of us have a fairly narrow gap. A thinner center area than what it looks like in your post might be needed and should still work fine because of the lack of substantial leverage in that location. I have similar looking locks on all three of my RV8 controls and would be happy to share what I?ve learned in use on 4 RV?s so far. If you need someone to test prototypes let me know.

I'll stop by and have a look. thx

[Snowflake]

If you made the front edge perfectly flat you could print that standing on the front edge and wouldn't need any supports...

[Steve Melton]

elongated center web adds some strength and give an eye point for install. build supports are simple for this so it's no trouble. it seems plenty strong but like Scott mentioned, the center web thickness may need to be reduced. this one fits an RV9. the RV7 has an increased angle. I plan to adjust the fwd hole position for this one slightly.

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0117_zps4abcpkrw.jpg

[dtw_rv6]

Steve,

My ailerons are so close together, I had to use .045 aluminum for a web on my gust locks... maybe you could use a slot and a "push lock" tab that would grab a hole in a thin piece of sheet metal instead of trying to print something so thin... User would have to fabricate a small triangle of aluminum with a hole, but it just might be more robust.

Don

[Steve Melton]

it's too tight, need to thin the web

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190113_153045_zpsopsb2rzr.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190113_153104_zpsvfthaobm.jpg

one would need to make a strap to attach somewhere here

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190113_161153_zpsblrgo75h.jpg

[Scott Hersha]

Looks like you have it attached at the flap/aileron joint. Is that what I?m seeing?

[Steve Melton]

Looks like you have it attached at the flap/aileron joint. Is that what I?m seeing?

yes, but it's too tight

[scsmith]

Steve,

Designing winglets that actually work to improve wing efficiency is one of the more challenging aero design problems in the airframe aero world.

Very easy to make winglets that actually increase drag compared to plain tips.

Even the experts with good CFD and good design tools end up doing numerous wind tunnel tests, testing several permutations about the base design, then picking whichever works best.

In my view, you need an airfoil cross-section, you need a taller, less swept winglet, and you need some understanding of how to undo the vorticity that is already present. Not an easy job.

Good luck. I would say, expect roughly design number 24 to work.

-Paragon
Cincinnati, OH

I've had great luck with first designs working well out of the box, but all your points here are spot-on.

[Scott Hersha]

Do you really want the aileron lock installed there? Flaps would need to be up, and if you inadvertently lowered the flaps with the lock still installed, something would have to give - either the flap, the lock, or the aileron. If you attach the lock at the outboard/fixed end, then you?re holding the aileron from moving against a fixed surface, the wingtip. That?s where mine is and it works very well, and when I?m at OSH or just about anyplace, I usually have the flaps down.

I used to fly DC3?s and we had split flaps on that bird, so we had to have an aileron lock on each side. If you lowered the flaps with both locks still installed, you would just about rip an aileron off the airplane. Not saying we are flying DC3?s but flaps extending beyond the limits of the aileron stops, which they do, will damage either the lock (desireable), or the aileron inboard rib flange/skin (likely), or flap outboard rib/skin.

[Scott Hersha]

Do you really want the aileron lock installed there? Flaps would need to be up, and if you inadvertently lowered the flaps with the lock still installed, something would have to give - either the flap, the lock, or the aileron. If you attach the lock at the outboard/fixed end, then you’re holding the aileron from moving against a fixed surface, the wingtip. That’s where mine is and it works very well, and when I’m at OSH or just about anyplace, I usually have the flaps down. Flaps extending beyond the limits of the aileron stops, which they do, will damage either the control lock (desireable), or the aileron inboard rib flange/skin (likely), or flap outboard rib/skin.

[Steve Melton]

Do you really want the aileron lock installed there? Flaps would need to be up, and if you inadvertently lowered the flaps with the lock still installed, something would have to give - either the flap, the lock, or the aileron. If you attach the lock at the outboard/fixed end, then you?re holding the aileron from moving against a fixed surface, the wingtip. That?s where mine is and it works very well, and when I?m at OSH or just about anyplace, I usually have the flaps down.

I used to fly DC3?s and we had split flaps on that bird, so we had to have an aileron lock on each side. If you lowered the flaps with both locks still installed, you would just about rip an aileron off the airplane. Not saying we are flying DC3?s but flaps extending beyond the limits of the aileron stops, which they do, will damage either the lock (desireable), or the aileron inboard rib flange/skin (likely), or flap outboard rib/skin.

that's a good point. better to lock at the wingtip.

[Scott Hersha]

Changed the previous post about the DC3 - its been a long time ago..... Actually the control locks were designed to prevent ripping the ailerons off with inadvertent flap extension because of failure to remove a control lock. They were designing for crew failure in the 1930?s!!

[Scott Hersha]

I can show you how I secure my control lock on (yours would be better) on the outboard end, using a bungee and a hook.

[Steve Melton]

I'll probably use an ASA plastic for these. Similar to ABS but UV resistant.

[David Paule]

One feature I insist on for control locks is something to prevent the pilot from inadvertently attempting to fly the plane with them installed. Not a reminder, like a flag, but some way to physically keep the pilot from getting into the airplane.

For my C180, I built one that blocks access to the pilot's seat.

Dave

[Steve Melton]

version 2. printed with ASA that has high UV resistance.

http://i1249.photobucket.com/albums/hh519/semelton500/cap5_zpsu9v2zmav.png

http://i1249.photobucket.com/albums/hh519/semelton500/cap4_zps6kmuh3w4.png

[Vlad]

One feature I insist on for control locks is something to prevent the pilot from inadvertently attempting to fly the plane with them installed. Not a reminder, like a flag, but some way to physically keep the pilot from getting into the airplane.

For my C180, I built one that blocks access to the pilot's seat.

Dave

Dave in my opinion on RV it's unnecessary. The lock is highly visible and a stiff locked stick will get a lot of attention even before the start up. We all have check lists, do we? :D

[MIKE JG]

Human beings, being....well.....human, can and will screw up the most simple of things like forgetting to remove a control lock prior to flight.

[Canadian_JOY]

https://www.youtube.com/watch?v=f9LkgxQojq8

Attributed to an elevator control lock not having been removed prior to taking off.

[Steve Melton]

this is without a doubt the most hazardous part we have ever produced.

http://i1249.photobucket.com/albums/hh519/semelton500/cap6_zps2o85rado.png

[rmartingt]

Dave in my opinion on RV it's unnecessary. The lock is highly visible and a stiff locked stick will get a lot of attention even before the start up. We all have check lists, do we? :D



https://aviation-safety.net/wikibase/wiki.php?id=83555 (https://aviation-safety.net/wikibase/wiki.php?id=83555)

https://www.ntsb.gov/investigations/AccidentReports/Pages/AAR1503.aspx

These are just the first two that come to mind.


If I make any kind of control lock it'll be something that blocks both seats when installed.

[rocketman1988]

Unfortunately, IF the unthinkable happens, expect to be on the list the lawyers will be calling...even if the event was no fault of yours.

That small piece of plastic, in today's litigious society, may end up costing more than you can possibly imagine...

It's really a shame but that is the reality of it...

[Steve Melton]

so simple but potentially deadly. check your controls.

http://i1249.photobucket.com/albums/hh519/semelton500/cap7_zps8npuf7fe.png

[Vigilante]

so simple but potentially deadly. check your controls.

http://i1249.photobucket.com/albums/hh519/semelton500/cap7_zps8npuf7fe.png

Steve, great product. Couple of questions:

Any chance to test fit for RV-14a? Any thought of including rudder lock? RV model available engraved avaiable?

If you offered a rudder lock one could connect the group together with a light cord making it difficult to get to the cockpit without removing for those concerned about safety...my 2 cents....

[Desert Rat]

The control lock on the Caravan works just like an oversized c172 lock, i.e. goes through the pilots yoke shaft. When it's installed, it covers up the start/ignition switch panel, so you can't physically start the airplane with it installed. It also locks the ailerons in neutral and the elevators in a slight nose down attitude so even if you could get rolling, you can't rotate and climb up into a stall.

There was a crash a few years ago where the operator was installing the lock upside down on their airplanes so the flag wouldn't scratch the switch panel. The kid hopped in and tried to blast off, couldn't rotate, ran off the end of a short runway (presumably still trying to get the control lock out), Crashed, Died.

You can build in safeguards, but you can't eliminate human error, no matter how bulletproof you try to design something.

[Steve Melton]

the only thing I can think of at the moment for the rudder would be a plastic piece to replace the metal one in the photo. I'll take a look at it. It would be bigger and V-shape to contour to the trailing edge.

http://i1249.photobucket.com/albums/hh519/semelton500/cap8_zpsew2q88rb.png

[Steve Melton]

Steve, great product. Couple of questions:

Any chance to test fit for RV-14a? Any thought of including rudder lock? RV model available engraved avaiable?

If you offered a rudder lock one could connect the group together with a light cord making it difficult to get to the cockpit without removing for those concerned about safety...my 2 cents....

Is the RV-14 aileron the same as the RV-10? I have dimensions for the RV-10 but the not the RV-14.

[N941WR]

Steve,

Can you design a control lock that attaches to the control stick? (I don't like external control locks for various reasons.)

I'm thinking of:
1. A piece that attaches to the control stick, just below the grip.
2. A piece that positively connects to the control stick attach point.
3. A pivoting piece that mounts under/behind the panel.
4. A Catch to hold the Control lock when flipped up under the panel.
5. The tube that connects stick catch to the under panel pivot can be made from PVC so the owner can adjust the length to fit their installation.

The rudder pedals can be locked separately, if needed.

Just a thought.

[Steve Melton]

Steve,

Can you design a control lock that attaches to the control stick? (I don't like external control locks for various reasons.)

I'm thinking of:
1. A piece that attaches to the control stick, just below the grip.
2. A piece that positively connects to the control stick attach point.
3. A pivoting piece that mounts under/behind the panel.
4. A Catch to hold the Control lock when flipped up under the panel.
5. The tube that connects stick catch to the under panel pivot can be made from PVC so the owner can adjust the length to fit their installation.

The rudder pedals can be locked separately, if needed.

Just a thought.

need to catch my breath. that's 5 point thought. may be a bit much for me but thanks for the message.

[Steve Melton]

ASA is an all weather plastic with high UV resistance. this one is black because ASA plastic is difficult to obtain in the color and size I need. They say red color ASA plastic is on the way to me. I have silver color ASA plastic. My thoughts on ASA is that it prints somewhat like ABS but the buildable angle is less. ASA prints hotter than ABS an one needs to be aware of the fumes and vent them because it contains Styrene. ASA is more expensive than ABS. ASA tensile strength is ~20% higher than ABS. The primary benefit of ASA over ABS is the spec difference in UV resistance. It is mentioned that ABS white color will turn yellow if exposed to UV ray for extended duration. So far, the ABS installed on my aircraft does not show any evidence of degradation but those components are primarily located in areas that are not exposed to UV rays.

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0122_zpsfstirnnj.jpg

[Steve Melton]

the only thing I can think of at the moment for the rudder would be a plastic piece to replace the metal one in the photo. I'll take a look at it. It would be bigger and V-shape to contour to the trailing edge.

http://i1249.photobucket.com/albums/hh519/semelton500/cap8_zpsew2q88rb.png


maybe something like this.

http://i1249.photobucket.com/albums/hh519/semelton500/cap9_zpshx3ltia7.png

http://i1249.photobucket.com/albums/hh519/semelton500/cap10_zpsjwave2up.png

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0123_zpse51myuhn.jpg

[Steve Melton]

elevator gust lock - prototype 1 for RV9. it has an eye hole to attach a bungee cord to the rudder gust lock. it would be installed by sliding it between the elevator horn and horizontal stab.

http://i1249.photobucket.com/albums/hh519/semelton500/cap1_zpsk9keety3.png

http://i1249.photobucket.com/albums/hh519/semelton500/cap2_zpsiakv1a3r.png


it is an alternate attachment method to this one.

http://i1249.photobucket.com/albums/hh519/semelton500/photo1_zpslrb56b7c.png

[Steve Melton]

first test fit. the concept appears to be viable.

my wingtips are not as good as my neighbor's RV-14 for the aileron to wingtip check. the fit on his was perfect. mine, not so much, but even with my fit the aileron was secure. I also check the fit of the aileron to flap.

rudder fit needs minor adjustment to allow for the thickness of the trailing edge to better seat the rudder. the angle was spot on.

elevator fit needs adjustment for the vertical height. pull test verified the elevator gust lock is secure.

I believe the installation of all three could be completed in less than a minute. very simple.

aileron to flap
http://i1249.photobucket.com/albums/hh519/semelton500/RHS%20to%20flap_zpssvdovylq.jpg

aileron to wingtip
http://i1249.photobucket.com/albums/hh519/semelton500/LHS%20to%20wingtip_zpslxjm0yda.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/RHS%20to%20wingtip_zpsf6w94ac6.jpg

rudder
http://i1249.photobucket.com/albums/hh519/semelton500/rudder%20GL%20installed_zpsy7drskbi.jpg

elevator
http://i1249.photobucket.com/albums/hh519/semelton500/elevator%20GL%20installed_zpsjgaxa3hd.jpg

I did not have a custom bungee so I added a rope.
http://i1249.photobucket.com/albums/hh519/semelton500/rope_zpsjcf5tpzz.jpg

[Steve Melton]

see updated analysis

http://www.vansairforce.com/community/showpost.php?p=1319932&postcount=859

[BillL]

Very nice work, Steve. I like this design, good control of the rudder with low forces, not like blocking the cables. And light too!

What do you think about a bungee (with a rope stop) for gust compliance?

[Scott Hersha]

Steve,
I?m no longer amazed at your level of engineering and load path calculating when designing and building these printed things - because I?m used to it by now! I like your rudder lock with the ropes, because it should work, and would be hard not to see it on preflight. One suggestion- on the elevator horn lock, try making the inboard end of it with a lip that overlaps the outboard elevator rib at the end of that gap. There is enough torque in that area to twist the control lock and allow the horn to extend enough to ?unlock?. I have a similar lock on my elevator made out of aluminum, with pads under the upper and lower angles, and the web made out of .032 (a thicker web wont fit in). I?ve seen this happen on mine until I made the aluminum angles long enoug to grab the elevator on the inboard end. I made an aluminum lock for the rudder that works the same way, but I like your rudder lock idea better because of what I just mentioned, and also because there is much less force on the lock at the trailing edge than there is in that horn/vertical stab junction.

[Steve Melton]

Steve,
One suggestion- on the elevator horn lock, try making the inboard end of it with a lip that overlaps the outboard elevator rib at the end of that gap. There is enough torque in that area to twist the control lock and allow the horn to extend enough to ‘unlock’. I have a similar lock on my elevator made out of aluminum, with pads under the upper and lower angles, and the web made out of .032 (a thicker web wont fit in).

yes, this piece needs some more work. I think I understand what your saying. There is opportunity to improve it. The web thickness = .10 inch so it may not work for some that have a tight fitting elevator horn. This first design has a high contact stress at the inboard upper edge where it contacts the edge of the horizontal stab skin. With a 51 lb load the stress exceeds maximum. This would cause the component to break down over time. I have some ideas that may reduce the stress. thx for your thoughts on this problem.

http://i1249.photobucket.com/albums/hh519/semelton500/elevator_zpsvymnokoh.png

[Snowflake]

Steve, why not block the rudder horn, as on the elevator? It would seem to be a more sturdy place to grab the structure.

[Steve Melton]

Very nice work, Steve. I like this design, good control of the rudder with low forces, not like blocking the cables. And light too!

What do you think about a bungee (with a rope stop) for gust compliance?

Bill, I like the idea of using a rope. Bungee is optional. When I install on mine I will just use a rope. a rope capable of 50 x 4 = 200 lbf should be plenty strong and not weigh much. all of the plastic gust lock parts combined (quantity 4) = .35 lb. the rudder gust lock plastic piece alone = .22 lb. it's beefy.

[Steve Melton]

Steve, why not block the rudder horn, as on the elevator? It would seem to be a more sturdy place to grab the structure.

I can't reach it.

[Steve Melton]

second test piece. enlarged the hole to .625 dia. added some finishing touches.

http://i1249.photobucket.com/albums/hh519/semelton500/RV-9-rudder_zpstyauvfyz.png

[Steve Melton]

extended flanges inboard and added a contact location at the web to the outboard rib. the web contact location may be able to slide behind the spar.

http://i1249.photobucket.com/albums/hh519/semelton500/cap3_zpsfy43dqw7.png

[Steve Melton]

the elevator gust lock with the tab on the web did not fit. the tab would not easily slide behind the elevator spar so I abandoned that idea.

I decided to increase the web distance and add a small fillet at the intersection to provide increase web contact area. The fit was good and overall web strength is increased.

The rudder wedge fit was good and when tied it centers itself. I discovered it is easy to install with everything pre-tied except the last knot. That way you only need to make one knot. I need to re-learn which knot is best. The range of motion of the wedge is shown by tape. The wedge slides to lowest position and stays there. Weight of the rudder wedge = .22 lb. I am confident this method is very secure. No more worrying about my rudder in windy conditions. From a mechanical point of view, the load balance is beautiful, especially when gravity is doing the work. :)

The minimum angle of the rope is about 5 degree to horizontal, so sin(5) = .087. .22 lb/.087 = 2.5 lb fwd forward force on the rudder from the weight of the wedge.

For a full gust with maximum impact of 50 lb at the rudder trailing edge, the rope tension = 100 lb since the angle of the rope to vertical = 30 degree. sin(30) = .5. 50lb/.5 = 100 lb. 100 lb rope tension x (sin 30) = 50 lb. This will result in a 50 lb load fwd force on the rudder. recommend a rope that is rated at 4x100= 400 lb.

The elevator is tight and secure. Movement = ~.050 inch.

ABS/ASA plastic does not scratch paint.

When printed with ASA UV resistance plastic, these parts should last the life of the aircraft.

http://i1249.photobucket.com/albums/hh519/semelton500/cap5_zpsar5diwp1.png

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190122_192357_zpsglkpslno.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190122_192344_zps7zkr5peu.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190122_185023_zpslipmddig.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190122_193234_zpsisirh6c1.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190122_183449_zps9k2sdwaz.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190122_183443_zpsdrhvlbbo.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190122_183841_zps0dsrzgoh.jpg

[Scott Hersha]

Steve,
NICE! That?s what I?m talking about. Very secure rudder, and elevators for -A models, and taildraggers too. How thin is the web on the elevator counterweight control lock?

[Steve Melton]

Steve,
NICE! That?s what I?m talking about. Very secure rudder, and elevators for -A models, and taildraggers too. How thin is the web on the elevator counterweight control lock?

the web = .1 inch. this will not work for some that have tight clearance.

[Snowflake]

Rather than having to tie it every time, how about using an elastic of some sort to give the ropes some stretch, and hooks or carabiners to clip onto the holes in the locks? You wouldn't want a long piece of bungee as that could let the rudder find some resonance point in certain wind conditions, but perhaps a 2-4" piece of elastic tied into the rope somewhere along the length would be enough to take up the slack?

[Steve Melton]

Rather than having to tie it every time, how about using an elastic of some sort to give the ropes some stretch, and hooks or carabiners to clip onto the holes in the locks? You wouldn't want a long piece of bungee as that could let the rudder find some resonance point in certain wind conditions, but perhaps a 2-4" piece of elastic tied into the rope somewhere along the length would be enough to take up the slack?

that could work. BillL mentioned that the bungee should have a rope stop if you went that way. For me, I will use a rope if I can learn how to tie a proper knot. What type of knot should I use? My rudder will need to depend on it. Also, what would be a good rope?

[az_gila]

that could work. BillL mentioned that the bungee should have a rope stop if you went that way. For me, I will use a rope if I can learn how to tie a proper knot. What type of knot should I use? My rudder will need to depend on it. Also, what would be a good rope?

If you use a rope you will need some way of keeping the lose ends off your horizontal.
You don't want rope ends flapping around in the wind scratching your paint work.

[Steve Melton]

If you use a rope you will need some way of keeping the lose ends off your horizontal.
You don't want rope ends flapping around in the wind scratching your paint work.

yes, I don't want flapping ropes. do mountain climbers use something for that?

[az_gila]

yes, I don't want flapping ropes. do mountain climbers use something for that?

Dunno, but a velcro cable cord organiser would probably work -

https://www.jrbicycles.com/media/catalog/product/cache/1/image/600x450/568aa07d0ae1c49051c779f1b2b1425b/k/i/kink_cable_straps_red.jpg

See the aviation aisle of your local Ace hardware :)

[Mike S]

I will use a rope if I can learn how to tie a proper knot. What type of knot should I use? My rudder will need to depend on it.


A rope ratchet might be good here------you could put a bungee segment in also to add a bit of "give" to the system.

https://www.roperatchet.com/

If you go that way, might be good to make up a different way to attach it, the hook is kinda big and clunky for this application.

[Snowflake]

Maybe just tying a couple of loops into the rope length, and then putting a bungee between the loops? That way if the bungee fails the rope at least has a finite extension length.

[Steve Melton]

I am going to try this rope and these knots. and with Gil's velco cable clamps for the rope ends.

rope
https://www.amazon.com/gp/product/B015Y818KI/ref=ppx_od_dt_b_asin_title_o00_s00?ie=UTF8&psc=1

halter-hitch
http://i1249.photobucket.com/albums/hh519/semelton500/halter-hitch_zpsf9rxevkf.jpg

farmers loop
http://i1249.photobucket.com/albums/hh519/semelton500/farmersloop_zpsglk16agu.jpg

[Steve Melton]

adding some finishing touches to the elevator gust lock. changed the hole to half moon.

http://i1249.photobucket.com/albums/hh519/semelton500/cap6_zpsf50goy9x.png

[Steve Melton]

In the hangar today I noticed I have a major error calculating the rudder area. I didn't have the drawing scaled properly in the software. I should have checked it by hand but I didn't. This time I checked it by hand and included a picture of the dimensions so you can double check me. Included updated analysis. Apologize for the error.

Rudder area = 1150 in^2 = .741 m^2

Wind gust = 35 m/s = 78 mph

Rudder wind load = 545 N = 122 lb force

Rudder gust lock lateral load = 122/2 = 61 lb force (half is carried by the hinges, half is carried by the gust lock since it is at the trailing edge)

Add load factor of 3 for possible impulse, 61 x 3 = 183 lb force

Analyze the gust lock for 211 lb (see rope load vector diagram 183 lb lateral,105 lb axial, 211 lb rope tension) rope tension load applied at the rope contact and restrained at the the inner most V shape edge and outer most end contact.

The maximum stress = 4 ksi. ABS material is capable of 4 ksi.

Safety factor for this part = 4 / 4 = 1 for ultimate gust impact loading.

For this current design, there is no stress margin.

http://i1249.photobucket.com/albums/hh519/semelton500/rudder%20dim%202_zpsltlwqwk7.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/rudder%20dim%201_zpsr8n2mdtx.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/rudder%20area_zpshhh9fmkp.png

http://i1249.photobucket.com/albums/hh519/semelton500/rope%20tension%20load_zpsyutq3zof.png

http://i1249.photobucket.com/albums/hh519/semelton500/wind%20load_zpsxsmr53ac.png

http://i1249.photobucket.com/albums/hh519/semelton500/VM1_zpscsezh7aw.png

http://i1249.photobucket.com/albums/hh519/semelton500/VM2_zpsacwekrz8.png

http://i1249.photobucket.com/albums/hh519/semelton500/VM3_zpsp2ignmnu.png

***********************

consider anti-splat or u-bolt type restraint at the rudder actuation lever.

183 lb impulse air load x 20 inches rudder width at centroid = 3660 in-lb
distance from lever attach point to rudder hinge center line = 4 inches (or so)

3660/4 = 915 lb forward reaction force acting primarily at the lower rudder rod end bearing.

***********************

[Steve Melton]

the model did not have restraint at the V-notch in the axial direction that created a false wedge effect. I corrected that. However, the stress of 4 ksi at the rope attachment did not leave any margin. I increased the thickness of the part and changed the hole to a half moon shape. Those two changes increased the area at the rope tie and decreased the stress.

For a 3x gust impulse force of 211 lb at the rope tie and an allowable stress = 4 ksi, these are the results:

rope tie area stress = 2 ksi (safety factor = 2)
V-notch wedge = 3 ksi (safety factor = 1.33)
outside flat face = less than 1 ksi (safety factor = 4)

part weight increased from .22 to 0.29 lb.

******************

http://i1249.photobucket.com/albums/hh519/semelton500/cap2%20V5_zpsmwcyk8tb.png

http://i1249.photobucket.com/albums/hh519/semelton500/cap3%20V5_zpsihbn0mzb.png

http://i1249.photobucket.com/albums/hh519/semelton500/cap1%20V5_zps4w29pjmg.png

http://i1249.photobucket.com/albums/hh519/semelton500/VM1_zpsbbx34j1a.png

http://i1249.photobucket.com/albums/hh519/semelton500/VM2_zpsa3jkigaj.png

http://i1249.photobucket.com/albums/hh519/semelton500/VM3_zps8zupmtu0.png

[Paragon]

Steve,

I like the fact that you're engineering this gadget with real numbers. So refreshing vs. the eyeball engineering that one so often sees on forums.

One possible thing to consider: The length of this device will determine how much of your rudder trailing edge is loaded up in a strong wind. Might want to attempt to check if the device needs to be longer to keep from creating a dent in the trailing edge area under worst case wind loads.

Might also want to relieve the plastic corners and edges slightly, curving them away from the rudder sheet metal, for just this reason - to keep them from digging into the rudder under worst case loads.
?

2nd topic: I'm interested to see any data you have on what level of performance improvement may have been attained on your RV-9A using all the various fairings vs. no fairings. One imagines you should see a couple of knots of "free airspeed".

Thanks for all your interesting posts.


-Paragon
Cincinnati, OH

[BillL]

Bill, I like the idea of using a rope. Bungee is optional. When I install on mine I will just use a rope. a rope capable of 50 x 4 = 200 lbf should be plenty strong and not weigh much. all of the plastic gust lock parts combined (quantity 4) = .35 lb. the rudder gust lock plastic piece alone = .22 lb. it's beefy.

I communicated poorly, sorry. I was thinking the rope can be pretensioned, but if they get wet or after load cycling might develop some slack (a potential failure mode). The location is not one where one might like to install it with a huge tension preload. The bungee was just a parallel section on the rope, maybe on the fixed length side, to keep some tension on the system (corrective action #1) if the rope gets lazy. Maybe that is overthinking the problem, and maybe the wedge just slides down and keeps the tension anyway. That brings CR alternative #2, a small diameter tension loop under the rudder to pull down on the Vee Block. That would correct for tension and eliminate any shock like CR#1 could allow.

Testing might lower the likelihood of the lazy rope scenario.

Keep the ideas flowing!

[Steve Melton]

this flap rode cutout shape has been good. I was asked for a plastic template for this shape. Visually locate on the rivets using a couple holes, tape the template in place and make the cut.

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190126_164246_zpsl8jnxsii.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190126_164343_zps8mdjaaka.jpg

[Steve Melton]

Steve,

I like the fact that you're engineering this gadget with real numbers. So refreshing vs. the eyeball engineering that one so often sees on forums.

One possible thing to consider: The length of this device will determine how much of your rudder trailing edge is loaded up in a strong wind. Might want to attempt to check if the device needs to be longer to keep from creating a dent in the trailing edge area under worst case wind loads.

Might also want to relieve the plastic corners and edges slightly, curving them away from the rudder sheet metal, for just this reason - to keep them from digging into the rudder under worst case loads.
…

2nd topic: I'm interested to see any data you have on what level of performance improvement may have been attained on your RV-9A using all the various fairings vs. no fairings. One imagines you should see a couple of knots of "free airspeed".

Thanks for all your interesting posts.


-Paragon
Cincinnati, OH

yes, a longer moment arm could prevent concentrated loading at the fwd edge. the mate of the gust lock and rudder is precise. that may help some.
since this piece is free to slide on the rudder trailing edge, it should maintain some tension in the rope at all times and hopefully limit the impulse loading.

this photo is of prototype 2. prototype 3 has increased thickness.

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190126_163957_zpslo9cfv7x.jpg

I believe I get ~3 knots gain with the fairings. Not huge but they are free.

[Steve Melton]

adding final print touches to rudder gust lock. one more round needed to make cosmetically perfect. this part is fully functional. final weight = .3 lb.

material = ASA (high UV resistance, tensile strength greater than ABS, slightly heavier than ABS). While the stress margin is adequate for ABS material as designed. ASA material will provide added stress margin.

I need to develop a method to pull test this part to simulate the loading. it will be the sacrificial lamb. if anyone has an idea how to do this let me know. it needs to be pulled with a force of 211 lbs or so at an angle and fitted with a shape similar to a rudder. load with a steel hook to provide maximum concentrated load.

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0005_zpsj3icka05.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/rope%20tension%20load_zpsyutq3zof.png

[Steve Melton]

a couple photos of the final part. it is a nice red color.

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0008_zpsev48zc6g.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0009_zpswuttreuw.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0010_zpsnn53dyta.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0011_zpsqvsubuxz.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0012_zpscmz9elty.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0014_zpsqcny9vdx.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0015_zpsdxt7clvz.jpg

[Steve Melton]

what you can't see is the internal structure. this part uses a gradually increasing perimeter thickness. Less at the edges and essentially solid at the center. it's tailored to put the material where the load is.

[Steve Melton]

what you can't see is the internal structure. this part uses a gradually increasing perimeter thickness with internal support. it's softer at the edges and essentially solid at the center. it's tailored to place the material where it is best served.


http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0008_zpsev48zc6g.jpg

[flysrv10]

Will u have a RV10 model?

[Steve Melton]

after the pull test and some field testing we will work other models. we will be able to do several colors but I like red.

this red rope is OK but I think a slightly smaller diameter would be better and easier to tie a knot. still looking for a good rope.

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190130_180344_zpsoggp3etn.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190130_180421_zpsdhwk1bzs.jpg

[David Paule]

Consider the "high-tech" double braids from the marine world. With their core of Dyneema or other fibers, they are very strong and not very stretchable. You can reduce the diameter considerably.

But be sure to get the ropes with polyester exterior braid. Look for a good hand with a grippable cover that is flexible. Something that's used for control lines rather than halyards. I've had good service from apsltd.com, but it's been a few years since I've had a sailboat.

Dave

[Steve Melton]

Consider the "high-tech" double braids from the marine world. With their core of Dyneema or other fibers, they are very strong and not very stretchable. You can reduce the diameter considerably.

But be sure to get the ropes with polyester exterior braid. Look for a good hand with a grippable cover that is flexible. Something that's used for control lines rather than halyards. I've had good service from apsltd.com, but it's been a few years since I've had a sailboat.

Dave

looks good, I purchased the Dyneema 1/4 inch rope. thx.

they know rope.

[Steve Melton]

this one is a challenge. I relocated the hole to outboard side and reduced the flange height to help spread the load and keep the loading in shear and not bending as much a possible. the rope pulls at a 30 degree angle at 211 lb load (211 lb is impulse loading, 3x the aero load). the load is concentrated at the inboard edge of the overhang and the corner of the web. elastic plastic analysis for strain is within limits for the bulk of the web so that is OK. Material property: ABS material strain to failure =0.3. there is some concern at the web upper corner were it is connected to the upper flange. that may tear at some point but is easily inspected from time to time.

http://i1249.photobucket.com/albums/hh519/semelton500/cap2_zpsu1vag7xn.png

http://i1249.photobucket.com/albums/hh519/semelton500/cap1_zps3romkaqw.png

http://i1249.photobucket.com/albums/hh519/semelton500/EPS_zpsykwxzhvl.png

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0019_zpscaufgslm.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0021_zpskiccnyce.jpg

[Steve Melton]

I made a fixture to duplicate the loading for the elevator gust lock and made a pull test. maximum load tested = 220 lbs (3x aero load at 78 mph). the part looks good. web thickness = .093 inches.

Printed material = ASA plastic, high UV resistance

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190202_145630_zpstd5yr8kq.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190202_145707_zpsvpeapug5.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190202_145722_zpsi06nvtkw.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190202_145728_zpsgc9q1wig.jpg

ready to pull

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190202_150227_zpsigzvtwto.jpg

two straps needed to pull. work up pull one at a time.

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190202_150906_zpsckii6erd.jpg

two good guys, Ray Parker and Bill Duffy

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190202_151931_zpsbs2ktfuq.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190202_154917_zpsc08n7aeu.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190202_155457_zpsn3umy8ui.jpg

[n981ms]

Could there be some sort of friction lock on the gust locks and ditch the knots. Wrapping the rope a couple of times around the rudder lock should provide enough friction there. Some shape like this

https://www.amazon.com/Nite-Ize-F9L-02-01-Large-Figure/dp/B001HN6CWY/ref=asc_df_B001HN6CWY/?tag=hyprod-20&linkCode=df0&hvadid=168463824956&hvpos=1o2&hvnetw=g&hvrand=14543773287339802090&hvpone=&hvptwo=&hvqmt=&hvdev=c&hvdvcmdl=&hvlocint=&hvlocphy=9011184&hvtargid=pla-310914063051&psc=1

might do at the elevator.

[Steve Melton]

Could there be some sort of friction lock on the gust locks and ditch the knots. Wrapping the rope a couple of times around the rudder lock should provide enough friction there. Some shape like this

https://www.amazon.com/Nite-Ize-F9L-02-01-Large-Figure/dp/B001HN6CWY/ref=asc_df_B001HN6CWY/?tag=hyprod-20&linkCode=df0&hvadid=168463824956&hvpos=1o2&hvnetw=g&hvrand=14543773287339802090&hvpone=&hvptwo=&hvqmt=&hvdev=c&hvdvcmdl=&hvlocint=&hvlocphy=9011184&hvtargid=pla-310914063051&psc=1

might do at the elevator.

I had the same thought earlier but decided to keep these as simple as possible. thx for the message.

[Steve Melton]

I know you keep your aircraft outside. If you would like to have the this gust lock kit let me know. The web thickness for the elevator gust lock = .093 inch. You need minimum .1 inch gap to allow them to fit.

If so, I need two dimensions from you and Amanda will take care of the rest.

Horizontal stab tip fairing max thickness across the trailing edge:
1. Left Hand Side
2. Right Hand Side

Use a vernier caliper if possible to achieve an accurate measurement. Amanda will keep the measurements on file if a replacement is ever needed. Send the dimensions and look for the parts in your mailbox soon.

Why make custom parts that fit perfectly?.... because we can.



http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20180624_070847_zpsfxfhybwz.png

http://i1249.photobucket.com/albums/hh519/semelton500/cap1_zpsjbvqiryj.png

[Steve Melton]

need a piece to hold the aileron gust lock in place. one place to secure is at the aileron hinge. add a small bungee.

I think I'll call Abby at FlightLine and have her make a nice bag for these gust locks to keep them orderly. Maybe leather.

http://i1249.photobucket.com/albums/hh519/semelton500/hook_zpsskvulzfv.png

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0027_zpsbmhaiszl.jpg

[Steve Melton]

a friend showed me a knot I could hang off K2 and be secure. 1/4 inch dia sailing line rope, ultimate tension = 2600 lbs, unbelievable.

I'm ready to head West to observe F-18 carrier landings for a couple days. I'll take a couple photos of the landings and grading. Then they catapult me off the ship. I've been warned to give good grades.

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0029_zps7ql47dxc.jpg

[Mike S]

Figure eight on a bight.

[Steve Melton]

Figure eight on a bight.

that's what he said.

[Vlad]

I know you keep your aircraft outside. If you would like to have the this gust lock kit let me know. The web thickness for the elevator gust lock = .093 inch. You need minimum .1 inch gap to allow them to fit.

If so, I need two dimensions from you and Amanda will take care of the rest.

Horizontal stab tip fairing max thickness across the trailing edge:
1. Left Hand Side
2. Right Hand Side

Use a vernier caliper if possible to achieve an accurate measurement. Amanda will keep the measurements on file if a replacement is ever needed. Send the dimensions and look for the parts in your mailbox soon.

Why make custom parts that fit perfectly?.... because we can.



http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20180624_070847_zpsfxfhybwz.png

http://i1249.photobucket.com/albums/hh519/semelton500/cap1_zpsjbvqiryj.png




Very interested Steve. Thanks to a Marine One I was repositioned to a parking spot with more favorable winds. Tailwinds were beating me for three years now it's all head wind :D

I will forward dimensions to you in a week or so. I removed the HS webbing due to some ice accumulations and I am wondering if it could be a factor in locking. The web really stiffens the fairing.

[Steve Melton]

yep, if the fairing webbing is too close the ice can lock up and freeze your controls. I remember you mentioning that happening somewhere way up North. I would have cut them out also. my fairing gap = .1875 inch and concave. no ice jamming wedge effect is possible without being cut by the edge in theory, who knows for sure without a test. the webbing will add the stiffness, without it the elevator gust locks will not work. let me know when you are ready.

[Snowflake]

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0029_zps7ql47dxc.jpg

Note that the knot, as shown, is compromised and can lose a fair bit of it's strength (were it to be used climbing K2). At the top-right side of that knot, you'll notice that the two strands cross as they come out from behind the free ends. If you work the knot to twist those two so they lay flat and parallel all the way through the "8", you will regain the full strength of the knot.

[Steve Melton]

I had some trace ice in West Texas. In San Diego KSEE showing the gust locks at Golden State Aviation to a couple of folks. I like it out here. Whirlwind propeller is across the street. Thx George for the ride to Avis. I think I saw you come over in your RV8 about an hour later.

[Steve Melton]

these guys are good. wet runway, day or night, pitching deck, it doesn't matter. I was honored to be aboard the Theodore Roosevelt for a few days. I was very PROUD to be an American based on everything I saw on that ship.

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0411_zpsx9gtxob1.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0412_zpsvk2ybho5.jpg

[Steve Melton]

San Diego to El Paso to Grove OK to Cincinnati, total = 10 hrs with a tailwind.

nice scenery and the gust locks worked perfectly.

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0613_zpsiywiacfe.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0664_zpskmb0mva8.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0638_zps9lhixenq.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0249_zps3iugnwmr.jpg



************

amazing 2 inches of rain in San Diego

not a drop of water in the cap or in the tanks

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190216_150701_zpsckupyhdr.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190216_150716_zpsvxtziij2.jpg

***********

my fortune cookie when I arrived San Diego. sometimes they get it right.

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0236_zpsandxnday.jpg

[Steve Melton]

RV-7 version

http://i1249.photobucket.com/albums/hh519/semelton500/cap1%20left_zps9g8d4mbi.png

[Steve Melton]

as an exercise I sketched up the Whirlwind 3-bladed constant speed prop hub from some photos and ran and analysis for stress and crack growth. based on my assumed loads for takeoff conditions (which should be relatively close) the stress levels were good and the crack growth rates are low. Material used 2014-T6. I do not know the Whirlwind material or actual dimensions but this was just to show that it can be a good design with adequate stress margins.

http://i1249.photobucket.com/albums/hh519/semelton500/cap1_zpsde3bfh0g.png

http://i1249.photobucket.com/albums/hh519/semelton500/cap2_zpssuqatkhz.png

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0245_zpsz1pugwwq.jpg

[Bill Boyd]

Steve I missed your post in real time about spending a few days on the TR. I was honored to do the same back in about 2007 courtesy of a nephew in the Black Lions squadron. The Tiger Cruise, standing on the flight deck during flight ops - literally a few feet from the Tomcats' wingtips during the traps and sleeping one deck below the catapult was an unforgettable experience. They are skilled and dedicated bunch who do us proud.

[Steve Melton]

Steve I missed your post in real time about spending a few days on the TR. I was honored to do the same back in about 2007 courtesy of a nephew in the Black Lions squadron. The Tiger Cruise, standing on the flight deck during flight ops - literally a few feet from the Tomcats' wingtips during the traps and sleeping one deck below the catapult was an unforgettable experience. They are skilled and dedicated bunch who do us proud.


ditto, I think I had the same bunk and it was going on way into the night. It was a pleasure to be aboard for a few days.

[rockwoodrv9]

Steve,
When you run out of places to fly, head on up to the Lansing area. Im stuck here without my plane. I fear I am losing the flying bug not having it out here!

[Steve Melton]

trial fit was very good on the left hand side but the right hand side web clearance was too tight. I reduced the web thickness from .094 inch to .068 inch and will test the load capability. flexibility of the .068 web is increased (which I like) and strength should be over 200 lbs.

continuing to work the rudder gust lock profile for a good fit. each model is slightly different.

http://i1249.photobucket.com/albums/hh519/semelton500/cap1_zpszhvrmoga.png


edit: pull test

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190327_194924_zpstzdrq9yh.jpg

**
sharp corner, not a tight fit, gap under

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190327_203041_zpsgxsuaylt.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190327_195803_zpsbyjxzopg.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190327_195814_zps1lp0vouu.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190327_201032_zpsn2db248x.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190327_201212_zpsvmh51xia.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190327_201206_zpss6w4e09q.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190327_201224_zpsaxtehzsm.jpg

[Steve Melton]

kicking around and idea for a tipper canopy release fairing. glue fwd canopy release lever to inside of the fairing with goop.

http://i1249.photobucket.com/albums/hh519/semelton500/cap1_zpswrgsghuc.png

[Ihttp://i1249.photobucket.com/albums/hh519/semelton500/cap3_zpswvewozzd.png

http://i1249.photobucket.com/albums/hh519/semelton500/cap2_zpsgqucel71.png

edit: test fit

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190327_202529_zpsmyenlgtu.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190327_202513_zps7xjckoi4.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190327_201925_zps7lnl04f9.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190327_185702_zps6zr5ushp.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190327_184038_zpsj2zytqye.jpg



http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190327_185714_zpsbtqvc2xz.jpg

[Snowflake]

kicking around and idea for a tipper canopy release fairing. glue fwd canopy release lever to inside of the fairing with goop.
Hmm... A few thoughts...


Goop = no. Anything added should be removable, IMO.
The forward lever rotates about an axis as it moves aft, so the rear of the fairing would need a gap between it and the fuselage when locked to allow for the tilt.
Could the flat section be eliminated and the curve of the fairing brought right to the fuselage skin at 90 degrees, both for aesthetics and for drag?
If you incorporated an arrowhead pointing aft into the part, it could also serve as an instruction for anyone wanting to open the canopy in an emergency.

[Steve Melton]

yes, I needs something more. what about a set screw on the lower side that contacts the fwd lever?

http://i1249.photobucket.com/albums/hh519/semelton500/cap4_zpshfvxk0yl.png

http://i1249.photobucket.com/albums/hh519/semelton500/cap5_zpsehaxlgxt.png

[rockwoodrv9]

Could you pin it on or use small screw on top, inset nut on bottom? I can't remember the exact movement necessary to work properly, but maybe a slot for the lever?

Nice Idea Steve.

[Steve Melton]

Could you pin it on or use small screw on top, inset nut on bottom? I can't remember the exact movement necessary to work properly, but maybe a slot for the lever?

Nice Idea Steve.

yes, it can be pinned. that may be the best way. I was trying to avoid drilling a hole. the new silver ASA (UV resistant) is really beautiful but I need to upgrade my nozzles because it clogs but I will get it to work. it really almost looks like this.

I don't believe I will need to slot mine but some might prefer it.

http://i1249.photobucket.com/albums/hh519/semelton500/cap6_zpsh2wjcwx6.png

**********

not too bad

http://i1249.photobucket.com/albums/hh519/semelton500/DSCN0920_zpsapspideo.jpg

[Steve Melton]

a couple of styles and colors. I opted for silver color, enclosed, fixed with a set screw RTV'd. I'll test that for awhile.

silver, slotted

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190330_140814_zps1aqj4l7j.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190330_140844_zpsuwievohm.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190330_141026_zpsqujtaoex.jpg

***********

red, enclosed

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190330_141343_zpskrvi0oei.jpg

*********

silver, enclosed, weight = 13 gm

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190330_135749_zpskruda46m.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190330_135654_zpswxvqfpu5.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190330_135631_zpsncfkldlr.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190330_135828_zpsb1ncmowd.jpg

[az_gila]

Steve, is the enclosed version a bit of a safety hazard?

No-one can tell that it an emergency release...:(

[Steve Melton]

Steve, is the enclosed version a bit of a safety hazard?

No-one can tell that it an emergency release...:(

yes, it could be a safety hazard. my canopy has a bulb seal around the edge and when released the canopy pops open and the lever swings all the way out of its own accord. if I was upside down it might not do that.

operationally it will be OK for me for testing. believe it or not, in five years I have never pushed on the release lever.

I'm not sure a random bystander would understand the original latch operation either without some large marking.

[Snowflake]

yes, it could be a safety hazard. my canopy has a bulb seal around the edge and when released the canopy pops open and the lever swings all the way out of its own accord. if I was upside down it might not do that.
Mine works the same way, I hadn't thought about that either.

But as a starting point, maybe if you printed an arrow with the first few layers of printing (like 1/16" thick?) and then printed the airfoil shape on top of that, the arrow would sit against the fuselage and point aft as instruction for what to do with that lump. Not perfect, but maybe a start? The arrowhead would need to be about twice the width of the airfoil to stick out.

[Steve Melton]

Mine works the same way, I hadn't thought about that either.

But as a starting point, maybe if you printed an arrow with the first few layers of printing (like 1/16" thick?) and then printed the airfoil shape on top of that, the arrow would sit against the fuselage and point aft as instruction for what to do with that lump. Not perfect, but maybe a start? The arrowhead would need to be about twice the width of the airfoil to stick out.

it's a good idea.

I sketched it on there but the fairing itself is small and the arrow is not easily noticed. it's probably better to placard the side of the aircraft with an "OPEN" label and an ARROW. I may do that.

[Bill Boyd]

Steve, do you make fairings for the RV-10 flap hinges?

[Steve Melton]

they are on my list and I believe they would look very good. after these gust locks I promise to get one them.

[Steve Melton]

I don't know if it was any faster but i looks better.

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190401_192823_zpsg9nksjx2.jpg

[Steve Melton]

RV-9 thin web (.064 inch) pull test

also, I took a hammer and cracked the web in the middle before the test

record pull to 280lb. by the time the rope stretched and I got the photo it has relaxed to 270lb.

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190401_190146_zpstmehz8ue.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190401_190215_zpssxlmcxlo.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190401_190542_zpsgzpgyhc7.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190401_190941_zpsycpurc5z.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190401_191002_zpsyfbt9htm.jpg

******

good distribution of stress along the web

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190401_191316_zpsbk1si5qy.jpg

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190401_191302_zpsli8ntiq8.jpg

[RV7A Flyer]

I don't know if it was any faster but i looks better.

http://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190401_192823_zpsg9nksjx2.jpg

I'm a bit confused...maybe just slow today :)...how's it work? You have to move the forward tab aft, then push in on the aft tab to swing the latch handle out. How do you do that with this thingie attached?

I like it, cause I'm always looking for little ways to make the plane look faster (and maybe gain that .01 knot to stay ahead of my buddy in his -7 LOL)...

[Steve Melton]

this little fairing only works because I have a bulb seal around my canopy and when released the canopy springs open. I have not used my canopy release lever in five yrs, so it works for me. otherwise, there is a slotted option.

these could be a safety hazard, so caution is advised. a random bystander may not know how to operate it.

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190330_140814_zps1aqj4l7j.jpg

[Steve Melton]

while examining the mold impressions of the RV8 rudder trailing edge, I found it is an elliptical shape. the trailing edge must be protected and the gust lock should not contact this shape except at the very aft edge. the resulting gust lock interface looks like this.

the RV8 rudder trailing edge is more robust than other models.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zps18jywpco.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap2_zpsb4fu412w.png

[Steve Melton]

simple and secure design. check the controls are free before flight.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpsq5cqciws.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap2_zpszjbg5ms1.png

[Saville]

Just a quick reminder - in case youa re looking for something to do (which I bet you'r e not ;) ):

A P-51 "fluted " throttle handle that slips over the standard cylindrical throttle handle. Extend it inboard somewhat and set it up to take a simple spring return PTT switch at the end of the grip.

[Bavafa]

simple and secure design. check the controls are free before flight.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpsq5cqciws.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap2_zpszjbg5ms1.png

Can't quit picture how these work, does the hole goes to the outer aileron hinge bolt and the arm gets locked to the bottom of the aileron on each side?

[Steve Melton]

a couple of items. I don't recommend silver for these but I wanted to take a look. silver is tough to print well.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN0955_zpsm3xrosvg.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN0924_zpsbbeiw9zu.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN0931_zpsyjxscaqm.jpg

[Steve Melton]

open the mark slightly. i looks good. 5 minute install.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN0933_zpsi40xbgq3.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN0935_zpsybpf1jji.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN0937_zpsiz6jlj07.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN0938_zpsoxxria6x.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN0943_zpsmtsyqu51.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN0949_zpsjdcjlcsp.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN0954_zpsih0vhvjv.jpg

[Steve Melton]

a set of gust locks for RV-14. the rudder gust lock is printed essentially solid in the center internally but tapers internally at the upper and lower edges. the contact profile is constant. this allows for high strength is the center but softer at the edges. if you look closely enough you may be able to detect the five internal process changes. printed with ASA plastic that has high UV resistance.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1008_zps6rsyfilb.jpg

[Steve Melton]

elevator gust locks are custom fit to measured dimensions. welcome to the age of custom fit.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1011_zpswtwjboap.jpg

[Vlad]

Steve,
Can you think of some sort of spike thingy on top of the rudder to prevent birds landing on it? It?s a disaster this year. :D

[flysrv10]

a couple of items. I don't recommend silver for these but I wanted to take a look. silver is tough to print well.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN0955_zpsm3xrosvg.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN0924_zpsbbeiw9zu.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN0931_zpsyjxscaqm.jpg

When will you be doing this for RV10?

[Steve Melton]

there is one RV-10 on the field at HAO but the owner has been ill with kidneys. I'm not sure when it will be available for measurements. it's on the list.

[Steve Melton]

Steve,
Can you think of some sort of spike thingy on top of the rudder to prevent birds landing on it? It?s a disaster this year. :D

I'm thinking metal spikes and plastic. I sketched a concept.

[Steve Melton]

a couple of incoming questions on these so I thought I would make a post.

the dampers are marine grade weather stripping and is very high quality. they can be rotated to extend life as the wear is seems to be on the outside edge. they can be rotated in a couple of minutes since they slide out in a track. I'll have Amanda add a replacement pair on her website if you ever need. low cost.

I have flown with these for a about a year and have about 100 hrs on them. they reduce the high frequency vibration, give good grip and are pleasant to have you feet resting on them for long trips. they do not adversely affect rudder application. they do not need any glue to hold them in place since they are trapped in the slot on the outside edge

https://oi1249.photobucket.com/albums/hh519/semelton500/boat_outfitters_zpsf0vwqpqs.png

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1068_zpsajo86too.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1070_zpsulk7ktr7.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1072_zpskgtzdeeg.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1074_zpsmsxgg4vh.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1075_zpsabf3aksk.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1076_zpsm387zmmz.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1077_zpspmqvsiye.jpg

[Radioflyer]

This has to be the longest thread ever on this forum and someone can be proud of that, I suppose. However, there have been a number of ideas and topics included here that could easily be separate threads in their own right and perhaps more easily discoverable/readable. Just saying...

[Snowflake]

This has to be the longest thread ever on this forum and someone can be proud of that, I suppose. However, there have been a number of ideas and topics included here that could easily be separate threads in their own right and perhaps more easily discoverable/readable. Just saying...
The search box is still the best way to find anything on the site... Anything off the topic of Steve making 3D parts for RV's is really the fault of the person posting something off-topic.

[Steve Melton]

another TAZ6 arrived today. we have the freshest plastic in town.

https://oi1249.photobucket.com/albums/hh519/semelton500/TAZ6_zpsifvudynk.jpg

[Steve Melton]

keep training and then fly

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1081_zpsmiivizdu.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1091_zps1yzsbaay.jpg

[Steve Melton]

I don't even think about the rudder anymore. No worries about if it is secure. It is secure.

Wichita Kansas, parked east / west.

Dropped off at Jabara airport.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1109_zpspcvtm1zl.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1106_zpsttm11cwl.jpg


Picked up at Jabara four days later.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1148_zpsv8tmf9hq.jpg


My tie down links are bigger than theirs.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1151_zpsltsdejv2.jpg

[Steve Melton]

I can't believe the bugs this year. could be because of all the water. bug blades are installed. it's the same set for the past three years. somewhere in Kansas.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1154_zpsfamingmh.jpg

[Saville]

Any chance you could reduce the size of your photos? Even the reply window gets shoved off screen.

[David Paule]

Many of the photos on VAF are 800 pixels wide, and that seems to fit well.

Dave

[Steve Melton]

some input from users about the angle of the arm allows the headset to to slide off. added option to allow users to choose the desired angle from 0, 5, 10, 15, 20 to 25 deg.

0 deg
https://oi1249.photobucket.com/albums/hh519/semelton500/0-deg_zpstvjp6wkp.png

5 deg
https://oi1249.photobucket.com/albums/hh519/semelton500/5-deg_zpsffqxrw4m.png

10 deg
https://oi1249.photobucket.com/albums/hh519/semelton500/10-deg_zpsjuxpm1io.png

15 deg
https://oi1249.photobucket.com/albums/hh519/semelton500/15-deg_zpsx3a5o6s0.png

20 deg
https://oi1249.photobucket.com/albums/hh519/semelton500/20-deg_zpswbptyv3r.png

25 deg
https://oi1249.photobucket.com/albums/hh519/semelton500/25-deg_zpslfqiatqf.png

[rv7charlie]

Couple of thoughts from down south. If you expect your plane to spend any time down here, don't ignore fuel vent protection. I've had one of our many variants of hole-filling critters go into -4 aluminum tubing that still had the tubing cutter burr on the inside, leaving ~1/8" dia hole (90* vent tubes on an RV-4) and almost totally block BOTH tank vents. Plane was fine a few days earlier.

On a similar note, I just found a mud dauber building in the pilot side fresh air vent, in my closed hangar.

Steve, will your rudder extensions fit with the screw bosses up, instead of down? With a floor in the plane (similar to your pics), I can barely get my dainty size 9s under the pedals; it would be impossible with anything lower on the pedals.

Charlie

[Steve Melton]

Steve, will your rudder extensions fit with the screw bosses up, instead of down? With a floor in the plane (similar to your pics), I can barely get my dainty size 9s under the pedals; it would be impossible with anything lower on the pedals.

Charlie

no, these only fit the orientation as shown.... but it's an interesting thought.

*************

as for bugs they are low probability items but high risk if it occurs.

[rv7charlie]

Down here in the dirty south, they are not low risk at all; they are an extreme risk. In summer, every orifice in/around my hangar, from ~1/8" up to & over 1/2", gets plugged by some variation of wasp or bee. As I mentioned, they don't even care about gas fumes. They will fill pitot tubes, tank vents, air vents; even the induction air intake, if you let them. If I don't plug the sections of hose hanging in my shop, they get filled.

A number of years ago on my always-hangared early '90s vintage -4 (with the factory supplied non-air cleaner air box) ran horribly on a takeoff run. I found a ~1 1/2" x 4" x 1/2" dauber nest lying in the airbox when I checked. It was out of sight on preflight, but shook loose on the takeoff roll & got crossways over the carb inlet.

Charlie
(just trying to help your sales with testimonials of what happens without...) :-)

[Steve Melton]

the trouble with bugs is that they get you when you're not looking.

[Scott Hersha]

One thing I?ve found that works with the #4 fuel vent line is a long nylon tie-wrap with a red flag threaded onto the ?business? end. Get one that fits snugly into the vent line (mine is just a #4 Al tube bent forward below where it comes out). Shove that long nylon tie-wrap into the vent line, snugly, with the red flag flapping in the breeze so you don?t forget it on preflight - although, I don?t think it would matter. It?s not air tight, but discourages insects from building their Casa in an unwelcome place. This has worked for me in northern Michigan, where a wasp will build a nest in any hole in a few minutes. ? if they could buck rivets, you could build an RV in a week....

[David Paule]

Steve, thanks for the photo resizing. Keep it up and it'll make a difference soon.

Dave

[Steve Melton]

kicking around a slip on bugcap for straight #4 tubing. remove for Winter flying.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpstnnod4ko.png

[Steve Melton]

the print is OK but could be better with a smaller printer nozzle because of the fine detail. the install method is to squeeze the tube sides and deform slightly then slip on the vent tube. it is secure. remove for winter flying.

since we don't want to reconfigure our printer for a smaller nozzle we don't plan to make these avail unless there is interest. if you would like the .stl file or SW file, let me know.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap3a_zpshu9f2lgh.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap3b_zps3ea6nhjj.png

[Steve Melton]

Amanda is printing some rib stamping blanks for a test run. She printed these both in the horizontal and vertical directions for evaluation. One has square corners and the other radius corners. Dimensions are ~ 4 x 5 x .75 thick. beefy ASA plastic parts.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1237_zps7we6rfxo.png

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1239_zpshxo3iocn.png

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1240_zpsqkk6zmgs.png

[Steve Melton]

getting around to the RV-10 for these test fit pieces.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1246_zpsbvuijkwl.png

[Steve Melton]

thinking about panel slot spacer. screws hole are for removal so as not to scratch the panel. custom sizes. ASA plastic, UV resistant.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpsz1meitlz.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap2_zpsgmdqwbzu.png

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1257_zpsmrp5vokl.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1258_zpsm9hupn5l.jpg

[flysrv10]

Where do you use this?

[flysrv10]

I will take a set for Rv20 when ready.

[Steve Melton]

Where do you use this?

it covers the hole in my panel below the transponder.

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190615_144859_zpsvbmotzsk.jpg

[Steve Melton]

I will take a set for Rv20 when ready.

I'm working it.

[Vlad]

Another idea for you Steve. I was removing a steam gyro the other day. Had a blank with me but forgot screws and nuts. Can you design a snap on blanks both in 3 1/8 and 2 1/4?

[Steve Melton]

Another idea for you Steve. I was removing a steam gyro the other day. Had a blank with me but forgot screws and nuts. Can you design a snap on blanks both in 3 1/8 and 2 1/4?

yes, I'll do that

[Steve Melton]

quick and dirty. may need a slight adjustment but that's a concept.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpserwjnpqe.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap2_zpsmdlubbxj.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap3_zpsuogcuwjw.png

***************

some adjustments made. take a look at the finished part tomorrow.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap4_zpshlolttle.png

[ALagonia]

A suggestion. How about a holder for the battery pack of my Bose headsets? Something my battery pack can slip into and that I can mount with maybe Velcro on my side panel.

[Steve Melton]

A suggestion. How about a holder for the battery pack of my Bose headsets? Something my battery pack can slip into and that I can mount with maybe Velcro on my side panel.

are there any part dimension avail? having the design space is usually the biggest hurdle.

[ALagonia]

are there any part dimension avail? having the design space is usually the biggest hurdle.
Probably not but I will check. I was thinking of something akin to a cradle like what you can put a mobile phone in for the car. Open faced so access to the on/off button and volume controls is easy.

[Steve Melton]

appreciate the request, but to have a nested fit I would need the design space. We don't have access to that at this time.

[ALagonia]

appreciate the request, but to have a nested fit I would need the design space. We don't have access to that at this time.
Understand. Thanks

[Steve Melton]

the result was not too bad for the first print overnight. the front surface could be smoother. the camera picks up every detail. I like setting records so I'll have Amanda ship it to you today. you install and fly in quick fashion. that would be "from thought to design, shipped, delivered and flying part in a couple of days".

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1259_zpscm6pt75i.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1261_zpsnnhfimmg.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1262_zpsojgqzkeh.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1263_zps5p5xpvej.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1265_zpsvfudlzlt.jpg

[Snowflake]

Steve, if you made the locking tabs end flush with the front surface, you could print the whole thing face down with no supports. Front surface would be as smooth as your bed, and text could still be included. You'd need to use a fingernail to unlock the locks, but this probably isn't something that will be removed and installed frequently anyway...

[Vlad]

Steve the mailman brought the cover today. Fits like a glove thank you very much! It's a record indeed. In less then two days from the design to manufacturing to flight testing. :D

https://i447.photobucket.com/albums/qq197/N666BK/Easing%20the%20maintenance/Steve%20Melton%20-%201%204.jpg (https://s447.photobucket.com/user/N666BK/media/Easing%20the%20maintenance/Steve%20Melton%20-%201%204.jpg.html)


https://i447.photobucket.com/albums/qq197/N666BK/Easing%20the%20maintenance/Steve%20Melton%20-%201.jpg (http://s447.photobucket.com/user/N666BK/media/Easing%20the%20maintenance/Steve%20Melton%20-%201.jpg.html)

https://i447.photobucket.com/albums/qq197/N666BK/Easing%20the%20maintenance/Steve%20Melton%20-%201%201.jpg (http://s447.photobucket.com/user/N666BK/media/Easing%20the%20maintenance/Steve%20Melton%20-%201%201.jpg.html)


https://i447.photobucket.com/albums/qq197/N666BK/Easing%20the%20maintenance/Steve%20Melton%20-%201%202.jpg (http://s447.photobucket.com/user/N666BK/media/Easing%20the%20maintenance/Steve%20Melton%20-%201%202.jpg.html)

Those bug covers came handy too.

[Steve Melton]

It is a record!

[Steve Melton]

from Amanda's desk

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1266_zpsxxrwawhb.png

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1268_zpsg5ivg9u2.png

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1269_zps7ysx4bau.png

[Snowflake]

Not enough threads showing on the Nylock... :) Otherwise, looks great!

[Steve Melton]

Amanda is printing this morning. It's nice to have a kid working. She mows the grass too with a push mower that not self propelled. She has worked grass mowing time down from 1.5 hr to 1.0 hr.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1278_zps7lk1hodh.jpg

[Steve Melton]

working to complete these RV-7 gust locks. should be finalized and uploaded to the web site by July 7th.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1283_zpsjxdri7kh.jpg

[WingsOnWheels]

This has probably been asked somewhere in the last 97 pages, but what material are you printing most of these items from?

For in-service items (other than around the house stuff), I have been using PETG. It is nice and strong and doesn't warp too much. I have had no luck with ABS. I would like to try nylon, but hear that warping is a problem as well.

[Steve Melton]

the gust lock material is ASA plastic. it is UV resistant. it the same material used for automotive car trim.

a printing tip is to maintain an uniform chamber temperature and circulate warm air.

when transitioning from thin to thick sections pay added attention to fillet integrity by laying in single extrusions to get an absolute complete fillet fill. this will give the strongest part. I've tested them. it makes a difference. these parts were pull tested to over 300 lb rope tension. it has good strength margin for 87 knot wind speed.

[Steve Melton]

I'm finally happy with this. Initially, I made the cover too thin and it bowed when installed. It worked fine but I didn't like the look. I stiffened it with minimal added weight. It is now secure, lightweight, and straight.

If you're making these, I used .080 arm with length to installed deflection = 10:1. That worked well. It is secure so there are screw holes to thread #6 screws to avoid scratching the panel when removed.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpsgupukzv7.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap2_zpsgmnlgtbj.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap3_zpsunorfar2.png

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190704_123404_zpsdmnk9lwf.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190704_124211_zpsrzdbgllm.jpg

[Steve Melton]

updated the design to make the snap fit stronger and added parabolic light diffusing features on the face. Amanda was the product tester, she squeezed the springs to maximum deflection 1000 times and the part retained its spring strength. Another Vlad inspired idea comes to life.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpsbrp3tqo5.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap2_zpskdrfyd4l.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap3_zpsd1ha8tkk.png

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1289_zpsreq5qczk.jpg

[Steve Melton]

In preparation for Oshkosh I decided to clean my flap fairings. I rarely look at these. All original since installation, never removed, as with all the plastic on my aircraft, it's original. They are in perfect condition after several years, hiding, doing their job.

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190706_135820_zps8o73wlfi.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190706_135755_zpswvrkr9r7.jpg

[Steve Melton]

as printed, black shows every defect but smoother. we are getting better. if I have time before Oshkosh, I may install this at position 2 for evaluation.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1293_zpswwx8cawt.jpg

[rockwoodrv9]

Steve, with all your speed mods you will be so fast you are probably already there!

If you get to the Lansing - Mason area, stop by and say hello.

[ALagonia]

Steve, with all your speed mods you will be so fast you are probably already there!

If you get to the Lansing - Mason area, stop by and say hello.
How much speed increases have you seen from these various aerodynamic mods?

[Steve Melton]

How much speed increases have you seen from these various aerodynamic mods?

will do. I like Michigan.

**********

the speed mods will give you 3 kts.

[Steve Melton]

RV7 and 9

compound angle drill guide, 5 and 23 degree

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpsqvh1p4tx.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap2_zpsasjdcq4i.png

[decathlon737]

Curious, wouldn't a left and right be required? Great idea.

[Steve Melton]

Curious, wouldn't a left and right be required? Great idea.

maybe so, I'll mirror another hole in the tool for RHS.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpssr4ng8nl.png

[Steve Melton]

Version 2

good fit but could be difficult to remove the block. it comes out but you need to tap it in your hand. a hole could be added on the bottom to push it out but what if the block length varies. I think a better solution is to cut the end off the tool. This will require a clamp to hold the block in position when drilling but should not be an issue. drill guide portion length is increased to give more life for this plastic tool.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap3_zpsmsdrx9jg.png

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190711_183121_zpsyxmhfb88.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190711_183138_zpsecyczbi0.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190711_183211_zpsl71quntv.jpg

[decathlon737]

I'm at this stage now, pm me with how to get one and I'll put it through the ringer :)

[Steve Melton]

I'm at this stage now, pm me with how to get one and I'll put it through the ringer :)

pm sent. put it through the ringer.

[dreed]

Great idea! I am past this stage and still recall trying to get all those angles just right in the drill press.

Are you printing in PLA or ABS?

[Steve Melton]

this is printed in ASA material. this will be a relatively inexpensive tool and can complete both sides. I will add drill bushings as a development project.

https://oi1249.photobucket.com/albums/hh519/semelton500/821-862_zpshhy1gobt.jpg

[Steve Melton]

RV7 and RV9

the first verdict is in for the tool and the enclosed box tool is preferred because there is no need for an additional clamp to hold the bock in place. no notable wear on the tool, clean holes, perfect alignment. 4 deep holes drilled in about 5 minutes.

the second verdict is pending tool evaluation, shipment, etc.

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190713_181050_zps6vrdpjoy.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190713_181115_zps8v7ekz32.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190713_181137_zpsjyzl2cbr.jpg

[Steve Melton]

pull test, over 20 lbs.

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190713_190917_zpsaam2tyld.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190713_190903_zpsrg6snjl1.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190713_190040_zpsmfarqaru.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190713_190023_zpsizehifzx.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190713_190118_zpsdvzftfor.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190713_190235_zps3amgcpzj.jpg

[Vlad]

Another idea for you Steve. Nose wheel pant towbar hole drill jig :)
PS; Many years ago a good friend of mine John Lewandowski milled one out of aluminum and it was handy.

[Steve Melton]

tweaking in the print

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1294_zps1ifhtyxs.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1295_zpsqx5itdba.jpg

[Steve Melton]

Another idea for you Steve. Nose wheel pant towbar hole drill jig :)
PS; Many years ago a good friend of mine John Lewandowski milled one out of aluminum and it was handy.

yes, that would be handy.

[RV8JD]

Steve,

I purchased your RV-8 aileron gust locks and they are nice. Are you planning on offering RV-8 elevator and rudder gust locks?

[Steve Melton]

the RV-8 is rudder gust lock is tougher that I originally thought. rudder thickness variation is more on the RV-8 than the others with trailing edge wedge rivet tail design. the RV-8 rudder is also more vertical than other designs which reduces the self centering and tightening characteristic. that being said I think it is still doable if you use a stiff rope like the Dyneema rope we have. I have molds of a couple of RV-8 tail trailing edges and have made some prototypes. I plan to take them to Oshkosh for more evaluation.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpsywmwliwx.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zps2zefkw93.png

[RV8JD]

the RV-8 is rudder gust lock is tougher that I originally thought. rudder thickness variation is more on the RV-8 than the others with trailing edge wedge rivet tail design. the RV-8 rudder is also more vertical than other designs which reduces the self centering and tightening characteristic. that being said I think it is still doable if you use a stiff rope like the Dyneema rope we have. I have molds of a couple of RV-8 tail trailing edges and have made some prototypes. I plan to take them to Oshkosh for more evaluation.

Thanks for the update. I'll stay tuned.

[Ted RV8]

To bad your gas cap lever tool is not made as a solid print like the products you?re showing in this thread.
Bought ten of them and they broke. All with different users. The tool was not a solid part.

[RV8JD]

To bad your gas cap lever tool is not made as a solid print like the products you’re showing in this thread.
Bought ten of them and they broke. All with different users. The tool was not a solid part.

Interesting. I have had their slim fuel cap opener for a long while now. I've been using it on both caps a few times a week, and it's holding up fine.

[Steve Melton]

was that a standard Vans' gas cap? I have my original slim opener on my key ring for several years.

[Ted RV8]

Yes the original Van?s fuel cap.
The tools I received were solid around the perimeter but the center fill material was not fused to the outer perimeter of the tool.
I?ll email you a picture if you like for you to post up and show what I?m talking about.

[Steve Melton]

Yes the original Van’s fuel cap.
The tools I received were solid around the perimeter but the center fill material was not fused to the outer perimeter of the tool.
I’ll email you a picture if you like for you to post up and show what I’m talking about.

yes, send it over and let's take a look

also, take a side view picture of your cap

[Ted RV8]

Send to the Amanda email or?

[Steve Melton]

Send to the Amanda email or?

better send to me because I don't think she will accept your email. I'll send you a PM with address.

[Ted RV8]

better send to me because I don't think she will accept your email. I'll send you a PM with address.

Well that?s interesting!!

Sent you pictures. Post the one of the tool up on this thread.

[Steve Melton]

this is the slim fuel cap opener. it is failed.

you can see the white over stress in the half moon and then tensile failure in the outer strands and then it peeled.

https://oi1249.photobucket.com/albums/hh519/semelton500/failed%20opener_zpsqnj15mma.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/failed%20opener%20cap_zpsgau3tg8k.jpg

[Steve Melton]

this same style (slim) fuel cap opener is 2.5 years old and has been used hundreds of times. still looks good but has pocket wear. I like it. it doesn't scratch the paint.

Ted, in bending, the outer part fibers carry the load. for the failed part, by the over stress fibers in the half moon, I calculate the lifting force on your cap lever to be greater than 6 lbs. that's asking a lot from a .15 inch width plastic hook used for prying. one approach is to relax the tension on the cap lever. this will also increase life of the cap lever roll pin. if the gas cap lever must so tight then I would recommend using a metal opener.

However, I will add another part to the list for the future, "the crowbar" fuel cap opener.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1298_zpsrecxzvym.jpg

[Steve Melton]

improved infill with updated software. we are getting better with help from others kicking us along.

old print style

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpsjs1jigkq.png

**
**

new print style

https://oi1249.photobucket.com/albums/hh519/semelton500/cap2_zpsdv5xpk45.png

**
**

new crowbar design for tight fuel cap levers. elliptical half moon shape for improved stress distribution. width = .25 inch with tapered end. includes tailored infill and printed in UV resistant ASA with higher strength.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap3_zps9qls2s9r.png

**
**

it's a beast with elegance

https://oi1249.photobucket.com/albums/hh519/semelton500/cap4_zpslvp64zmz.png

**
**

this will increase the cap lever lifting load capability from 6 lbs for the slim opener to 22 lbs for the crowbar. a 360% increase.

https://oi1249.photobucket.com/albums/hh519/semelton500/crowbar_zps413tk7fj.png

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1309_zpspsggivwn.jpg

[FinnFlyer]

Does anyone have a 3D CAD model of a stick grip they want to share?

Room for hat-switch, PPT, toggle switch, etc.

I'm planning on adapting an old PC 3D joystick, but would consider printing one.

Finn

[xavierm]

https://www.thingiverse.com/thing:776116

[FinnFlyer]

https://www.thingiverse.com/thing:776116

Thank you!

Looks like he's using the Arduino Joystick module which have pots rather than four switches for X-Y movements (in addition to a switch when you press down on the hat). This opens up the possibility for variable speed trim depending on how far you push the hat in X and Y directions. Nice!

Finn

[Steve Melton]

first install review comments:
"I opened the hole to 17/64 (to fit the canopy pin diameter) it works perfect. it is slick as hail."

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_5948_zpsloxfblpa.jpg

the hole size on the tool is .245. run a drill bit thru the tool hole to ream to the final size drill bit to maintain a tight hole. then cut the nylon block hole with the final size drill bit. between plunges you may cool the bit in water to prevent overheating the tool thermoplastic. we didn't do cool the bit on the four test blocks that were cut for this user and it was fine but it may be beneficial to extend the life of the tool.

the second user input is pending.

I'll take several of these Canopy Drill Block tools to Oshkosh and put then in a box on a picnic table for review. I don't have any nylon blocks. If you have one and are interested, bring it to check the fit.

**

a couple of folks are asking how we set the dimension for the hole because there are limited dimensions on the drawing. the tool hole was set exactly to the Van's drawings by matching the drawing in CAD.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap4_zpsidubu0dz.png

[Steve Melton]

We have multiple printers and nozzles and use this calibration block to verify dimensional accuracy. There are also a couple holes in the pillars lower surface. If you would like a copy of the SW file send Amanda an email.

https://oi1249.photobucket.com/albums/hh519/semelton500/cal-block_zps3ikwqisu.png

[Steve Melton]

When a long time multiple builder develops a new build method I tend to listen. Bill Duffy requested the canopy block drill tool to develop a new method to build the RV7/9 sliding canopy. He thinks he may have found a better way. I'll post his photos. You can discuss with him at Oshkosh. I don't know much about it, I have a tipper. Bill's RV-14 is cream color with an eagle on the side and has both an RV-7 and 9 sliders under construction.

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_5963_zpsh6zfocwq.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_5964_zpssysix5fp.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_5965_zps5kkicimo.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_5967_zpscy4cgzb3.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_5968_zps912fidog.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20180421_141946_zpsbzijqrts.jpg

[Steve Melton]

we have been using this style of large filament spool stand for several years. it's as compact as possible and can handle 5 kg spools and it's one piece. build weight = .75 kg. size = 8 inch width, 11 inch deep, 8.5 inch tall. send Amanda an email if you would like a copy of the SW file.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zps43tsac65.png

[Steve Melton]

wind damage to a poor soul.

https://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190726_141206_zpsbl1nk7aq.jpg

[sbalmos]

Well ****... though I'm not fully surprised. Oh well, another thing to do.