a couple printed ideas [Archive] - Page 5

sbalmos

07-27-2019, 07:04 PM

To be fair, there already was a small puncture before OSH. Those winds we have between the hangars at HAO can't be helped much when I'm getting my hangar door closed before a flight. But the winds yesterday and today had me worried. It already was on my list to switch to a pedal/stick gust lock. These AirGizmos paddles just aren't doing it for me, IMO.

Just means I stop by Spruce or somewhere in the morning to pick up some speed tape to patch it before I launch home.

Steve Melton

07-27-2019, 07:41 PM

Scott, we did the best we could with what we had to secure the rudder. I applied yellow tape to hold the rudder. Ray applied a tape to the hole. Greg left a note. We all tried to contact you but could not find a number.

sbalmos

07-27-2019, 07:52 PM

THANKS. No biggie. I just stopped at Menard's before dinner tonight to pick up a roll of super strength Gorilla Tape. The number on my prop card was my mobile.

Already building a parts list. I'm sure it happens to at least one person at each windy show. Lick wounds and move on. At least it wasn't painted yet. :D

Steve Melton

07-28-2019, 05:05 AM

you may want to stop drill the sharp corners and use alum speed tape. there is reported low IFR, fog, South of Oshkosh beginning at Dodge, Sunday 7/28 AM. give the day plenty of time to burn that off.

Unexpected aircraft problem while visiting AirVenture? Is something broken, need adjustment, need filling or recharged? Contact or visit the volunteers of EAA Chapter 75 operating the Emergency Aircraft Repair facility, located just south of the Hangar Café about the mid-point of runways 18/36. I could not find their number.

or.... Aircraft Maintenance (Off-site)
Basler Flight Service (920-236-7827) and NewView Technologies (920-303-0709) provide aircraft maintenance services.

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190726_141157_zpsty6c5uzd.jpg

Scott Hersha

07-28-2019, 05:55 AM

Scott,
This can probably be patched, but if you decide to build a new rudder (I would), I can help - I have the time, and, um, the place for a while at least. Of course you don?t need to order new fiberglass bottom or top, or new rod end bearings.... or a new trim wedge. Simple fix!

sbalmos

07-28-2019, 06:13 AM

Yup, I'm building a new one. Not worth it by the time I drill off the skin, probably bend the trailing edge (it's got 2012-era RTV), etc. I'll save the fiberglass, hardware, counterweight, etc like you mentioned (figured such already).

I'm not leaving here until 11am CT anyway, by the time I return the car, get a terminal bus, patch things up with the Universal Repair Weapon, etc. Going around west of Chicago. Maybe 2.5h.

Anyway, back to the 3D printing thread. I've side tracked it enough. :D

Steve Melton

07-28-2019, 06:15 AM

take your time. there is nothing more important than getting you home safely.

call me on this number if you have trouble and I'll come to meet you.

five one three two nine zero six two four six

Steve Melton

07-28-2019, 05:59 PM

Scott made it home in fine shape with tape on the rudder.

it does make me wonder if someone could create a DASH service for RV rudders/ailerons/wingtips. Perhaps make a fixture to the bottom of the aircraft that could be used to haul a these for DASH delivery.

maybe one in Kentucky and the other in Colorado?

Steve Melton

07-28-2019, 06:28 PM

RVPlastic is preparing for Nylon/Carbon fiber. Perhaps to build the ultimate fuel cap opener. Hopefully, it will not scratch thru pocket material.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1323_zpsiv9edfo4.jpg

rockwoodrv9

07-28-2019, 06:57 PM

Steve, Scotts damage and you last post made me wonder if you could make a round, flat "patch" that a person could epoxy on that would get a person home.

Maybe even a design of some harder plastic, that could be installed on the edge of the elevator and trim tab with a flat surface that might keep it from the sharp edge cutting into the rudder?

Just a thought.

sbalmos

07-28-2019, 07:22 PM

Okay, now that I'm awake from my nap and seeing this, it has me thinking of a variant of what Rock is thinking. Even a corner cover of plastic is going to make a nasty dent. So I think what might be interesting to prototype is a larger pair of triangular inserts, shaped to match the gaps between the neutral-position elevator / trim tab and neutral rudder, connected by a bridge piece that is shaped to fit over the neutral rudder trailing edge. Maybe not fully in contact with the rudder, but filling the gap enough that a gust will not generate enough kinetic swing of the rudder to make a dent when it impacts the plastic.

My fundamental problem this week was exactly what AirGizmos warns of in their instructions, albeit mentioned only for the 10. The 9A rudder is too tall for a person standing on the ground to reach up and slip into the counterbalance swing slot. The AirGizmos instructions mention needing to use a ladder to reach it. Who, honestly, is going to have a ladder in the majority of the places where they fly out to and use those paddles? In reality, this situation affects the 10, the 9A, (probably) the 7A, and I'm betting the 14A. No idea about the 12, although I saw a number of the Teenflight 12s' rudders at OSH also flapping in the wind. Your only protection at that point is whether you built your rudder horn stop brackets right!

Snowflake

07-29-2019, 07:52 AM

I still think the best rudder stop is the U-shaped metal rod that goes between a hole in the rudder horn and a hole in the rudder stop... Just be sure to hang a long red flag from it so you'll see it in your pre-flight...

That said, and building on Rock's idea above, what about a larger patch that could be epoxied onto each side of the rudder right where the elevator would hit it (to distribute load across a wider area), *and* an insert for the tip of the elevator, to make it less sharp? That would reduce the damage if things start blowing around. Of course it would still be better to stop the motion entirely.

sbalmos

07-29-2019, 08:08 AM

Never heard of the metal rod idea. Sometimes it's the forehand-slapping "why didn't I think of that? it's so crazy and simple, it just might work!" ideas that are best.

To be clear on the patch idea though... A temporary patch for a rudder puncture isn't necessary. A few layers of heavy-duty Gorilla tape or equivalent worked perfectly fine for me. The puncture is a puncture, but it's not like it's /HUGE/. It's the size of roughly the end edge of the elevator trailing edge wedge, which is what had enough force to puncture and tear the skin.

I don't think we're talking about making a kick-plate patch that would be patched on a perfectly fine rudder, as a preventative measure, are we?

rockwoodrv9

07-29-2019, 08:59 AM

I was thinking of a elevator cover with a type of fin on the edge that hits the rudder. It may screw with aerodynamics so that may be a non starter. Even a cover that makes the edge not as sharp would help with damage.

It would not be as good as a rudder stop, but could help.

Steve Melton

07-29-2019, 09:45 AM

It may be simpler to never let it occur.

sbalmos

07-29-2019, 09:54 AM

Surely, you jest. :eek::D

Steve Melton

07-29-2019, 10:04 AM

Surely, you jest. :eek::D

Scott, next year at Oshkosh please upgrade your tie downs and fully engage them. the beagle screws can fail and could possibly damage another aircraft.

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190726_141244_zps8goobbni.jpg

Snowflake

07-30-2019, 07:35 AM

I don't think we're talking about making a kick-plate patch that would be patched on a perfectly fine rudder, as a preventative measure, are we?

That *is* what I was suggesting, but I don't think it's the ideal solution. Much better is to prevent the motion in the first place.

Steve Melton

07-31-2019, 09:44 PM

we are not there yet but are relearning how straight lines can benefit a design.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpsjaayiaeu.png

**

final profile. straighter and smoother lines. designed to grab more towards the lever edge instead of next to the cap stem for improved lifting force. this design will not scrape on the lever edge and will not leave any scraped plastic particles. removed holes for straighter build lines and is a faster print. improved printed technique. strength increased 85%.

standard 2.0 inch length and new 2.5 inch length - material is same ABS and will add red/black ASA. same thickness dimensions: slim = .15 inch thick. fat = .18 inch thick. these should be fine for most have a smooth feel. we plan to eventually add a nylon/graphite version that will increase stregth further but I'm not sure if it will become rough in the pocket over time as the nylon wears and exposes the graphite fibers.

side note: excessive fuel cap lever tension will fail the fuel cap lever roll pin hinge over time. you can extend the life of the pin by reducing the cap lever tension by adjusting the nut on the bottom of the cap and keeping the hinge lubed. I spray the cap lever area with LPS1 and cycle the stem a couple of times. my caps are six years old, original, doing fine, but I carry a spare cap just in case.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpseipmchdx.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap2_zpsqtsdratz.png

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1339_zpsetnowpxs.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1337_zpszo9xm4ej.jpg

Steve Melton

08-06-2019, 05:56 AM

I don't think about my rudder being secure anymore. Make one knot and it's done. I need to factor in an extra 30 minutes for departure to answer questions about the plane from bystanders.

I do need some kind of gust lock storage so I don't need to untangle the rope every time. Throwing them in a bag isn't cutting it anymore. I'll have Amanda call Abby at Flightline Interiors this week to see what she can do.

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190802_174102_zps43yhmacw.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190802_174117_zps8rco0nop.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190802_174041_zpskqbiewdz.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190802_174112_zpsqvbstqlo.jpg

**

Burlington VT, beautiful country.

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190805_110438_zpspnjcjvpn.jpg

**

Lake Placid

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190802_170205_zpsxve63wwb.jpg

Snowflake

08-06-2019, 08:43 AM

I do need some kind of gust lock storage so I don't need to untangle the rope every time. Throwing them in a bag isn't cutting it anymore.

How about one of those dog-bone-shaped things people use to wrap up their iPod headphone cords so they don't tangle? You might have a way to produce a larger version for the ropes... :)

Steve Melton

08-07-2019, 09:04 PM

fuel cap opener. this is the very first print using this material and I am guessing at the parameters for my machine. some work to do but encouraging. the texture is rough but not as bad as I thought it would be. the part is very stiff. the material properties are multiple times higher than anything I have printed before and the filament itself feels like bailing wire. it requires a hardened steel nozzle for wear issues. really quite amazing. Amanda stuck it in a door jam and tried to break it but only crushed the wood.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1342_zpstwdb6auv.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1341_zpsahblvhmb.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1343_zpsx62ajfu1.jpg

Steve Melton

08-07-2019, 09:19 PM

How about one of those dog-bone-shaped things people use to wrap up their iPod headphone cords so they don't tangle? You might have a way to produce a larger version for the ropes... :)

a dog bog is a viable option.

I want something to not only organize but to help ensure all the pieces are visible in a pouch when I put them away (rudder / elevator / ropes / and aileron lock) and that can fit beside my seat in a pouch so they don't tangle with anything else. I gave Amanda Abby's number said go do it. I'll see what she comes up with.

Steve Melton

08-08-2019, 02:35 PM

Amanda's first concept for a travel pouch. She can take some height out of it and optimize the spacing but it meets the design requirements. She will work with Abby at Flightline to fine tune. I'm thinking leather.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1345_zpselpdvdzz.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1346_zps6kbxmtwp.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1348_zpsox7yyr0z.jpg

Bicyclops

08-08-2019, 02:51 PM

wind damage to a poor soul.

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190726_141206_zpsbl1nk7aq.jpg

Looks like those rudder stops need to be a bit bigger. I know that when I'm slipping, I go for all the rudder and modulate ailerons. I see scratches where the elevator scraped up and down before the puncture event.

Ed Holyoke

Steve Melton

08-09-2019, 09:47 PM

Amanda sent her gust lock travel pouch design to Abby for fine tuning. It will be fun to watch their design process.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1352_zpsf83qgjjs.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1353_zps8okw06s2.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1355_zpsjnazldla.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1357_zpsdbd7q5g8.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1358_zpssfyjpr3n.jpg

Steve Melton

08-10-2019, 08:30 AM

the fat fuel cap opener nylon/carbon fiber challenge. take two pair of pliers, grab it and try to break it. you can't do it.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1379_zpswwaoges6.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1378_zpshenlwhvq.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1376_zpsj0b4tlvl.jpg

Steve Melton

08-10-2019, 09:38 AM

My wife reposted these today on Facebook so I get to see them again. I was thinner and worn out from building. Building an airplane is hard work. It's been worth it. Good times!

Respect your fellow builders and lend a hand where you can. It will all come back to you.

note: I still miss Jon Thocker who gave advice and took the time to fly chase for me. RIP

https://oi1249.photobucket.com/albums/hh519/semelton500/741125_693346874024887_922475001_o_zpsuushosfn.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/1150606_693346970691544_950875554_o_zpsgcdlqil8.jp g

https://oi1249.photobucket.com/albums/hh519/semelton500/1167091_693347024024872_213930329_o_zpsjxtw7swq.jp g

https://oi1249.photobucket.com/albums/hh519/semelton500/1172293_693347124024862_120069219_o_zps0ksw6nfo.jp g

Steve Melton

08-11-2019, 06:28 AM

Dave Schuler had an idea for a mirror mount from the Kroger rail. Needs to be light weight. We will give it a try.

This is prototype 1.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpsqtcxzhiz.png

**

Mounts to the canopy sunshade rail.

https://oi1249.photobucket.com/albums/hh519/semelton500/edited-image_zpssrdngv2t.png

Steve Melton

08-11-2019, 03:41 PM

Check your six. Very light weight but stable. I like it. Hand is for camera focus.

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190811_132228_zps9tskoklw.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190811_132249_zpswxw0q4yh.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190811_132358_zpsutsmd67d.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190811_132645_zpszihnyiwy.jpg

*******

needs a nice thumb screw and pulled forward for access to move the mirror with ease.

I think we will make our own to be something like this. It's going to be nice.

the prototype is ABS material but the final product parts will all be ASA material to be UV resistant.

https://oi1249.photobucket.com/albums/hh519/semelton500/thumb%20screw_zpsznqpd5xy.png

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190811_132454_zpsq2bvziaw.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190811_133709_zpsuuoskr7b.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190811_135742_zpsyd6as161.jpg

Steve Melton

08-11-2019, 03:44 PM

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190811_142631_zpsnqbfcooh.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190811_142658_zpsqqh26hlt.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190811_142645_zpsd22zzlzp.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190811_142710_zpsutkhqs7n.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190811_154243_zps6inbxvsb.jpg

Steve Melton

08-11-2019, 03:55 PM

this stick cover served my well for 3 yrs but doing a transponder upgrade I cracked it by leaning hard into it laying under the panel. I increased the thickness by .010 and added some new print technique. It's stronger and better than ever and also water tight. No worries from a broken trim tab switch when climbing in and out.

old unit.... served me well but time for an upgrade.

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190811_151706_zpsot09jbpo.jpg

*****

new unit... water tight

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190811_151647_zpsxx86uxyb.jpg

filled with water. bone dry.

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190811_125623_zpsmgubn8lm.jpg

again, filled with water for hours. bone dry.

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190811_144602_zpsj2fwes41.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/xsect_cap1_zps8eifbq9s.png

Snowflake

08-12-2019, 08:06 AM

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190811_133709_zpsuuoskr7b.jpg
Steve, does the mirror sit far enough forward that it feels natural to use? Or do you have to think about sitting back to get your head far enough back to use it? In the side view it looks like it's quite a ways back from the panel.

aparchment

08-12-2019, 09:57 AM

Steve,

I blame you for getting me hooked on 3D printing!

Can you share any specifics on getting the carbon reinforced plastic to print well? Temps, feed rates, nozzle material and aperture, etc. I can't recall if you are using a Bowden style machine or not. Anything you can share would be much appreciated.

Antony

RVPlastic is preparing for Nylon/Carbon fiber. Perhaps to build the ultimate fuel cap opener. Hopefully, it will not scratch thru pocket material.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1323_zpsiv9edfo4.jpg

Steve Melton

08-12-2019, 10:05 AM

Anthony, We are fairly new to Nylon/Carbon fiber. Testing so far for me has been surprisingly good. Hardened steel nozzle .60 mm dia., nozzle temp = 260C, bed temp 110C first layer then 95C. print speed is low = 25 mm/s. no cooling fans. ooze is high, minimize retraction. lift the nozzle between layers as needed. I'm glad you are enjoying it. It's going to get even better with new materials. No Bowden, Lutzbot TAZ6 standard single extruder. Nylon is hygroscopic so keep it in a dry location during storage. Steve

Steve Melton

08-12-2019, 04:25 PM

now I need an eductor fairing or maybe a hole for a tube is good enough. <smile> it has combined uses and my wife says it's gross.

how would you make a single piece part like this? OK, maybe you wouldn't.

https://oi1249.photobucket.com/albums/hh519/semelton500/Infinity%20stick%20cover%20with%20relief_zpsvjy6bq ia.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpsswe9eupv.png

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1380_zpspdg6rfvu.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1381_zpssdqospzc.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1382_zpsqmkyo7iw.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1383_zps15z0rju7.jpg

Steve Melton

08-12-2019, 05:20 PM

Steve, does the mirror sit far enough forward that it feels natural to use? Or do you have to think about sitting back to get your head far enough back to use it? In the side view it looks like it's quite a ways back from the panel.

it seemed OK. I couldn't see much to my left but more than I needed to the right. so I'll make some angled options to test but for the first flight test, I liked it.

Steve Melton

08-12-2019, 08:59 PM

making selectable angles - option for 3 degree increments or so. pretty cool. plan to add a printed thumb feature to the screw for ease of adjustment or removal. these will be inexpensive. ASA UV resistant plastic white has the color of white nylon.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpscirvnjdz.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap3_zpszu4nn1y9.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap2_zpshmkzz8qa.png

aparchment

08-14-2019, 03:37 PM

Thanks Steve!

Anthony, We are fairly new to Nylon/Carbon fiber. Testing so far for me has been surprisingly good. Hardened steel nozzle .60 mm dia., nozzle temp = 260C, bed temp 110C first layer then 95C. print speed is low = 25 mm/s. no cooling fans. ooze is high, minimize retraction. lift the nozzle between layers as needed. I'm glad you are enjoying it. It's going to get even better with new materials. No Bowden, Lutzbot TAZ6 standard single extruder. Nylon is hygroscopic so keep it in a dry location during storage. Steve

Steve Melton

08-15-2019, 05:28 PM

the first two numbers are pitch. the second two numbers are yaw, positive right and negative left. 3 degree increments such as:

18 degree pitch and 00 degree yaw = 1800

https://oi1249.photobucket.com/albums/hh519/semelton500/1800%204view_zpssrhdvceu.png

******

18 degree pitch and 09 degree yaw right = 1809

https://oi1249.photobucket.com/albums/hh519/semelton500/1809%204view_zpskwcyicgy.png

*******

15 degree pitch and -06 degree yaw left = 15-06

https://oi1249.photobucket.com/albums/hh519/semelton500/15-06%204view_zpsljtae9o8.png

*******

21 degree pitch and -15 degree yaw left = 21-15

https://oi1249.photobucket.com/albums/hh519/semelton500/21-15%204view_zps3e3yery4.png

**
**

https://oi1249.photobucket.com/albums/hh519/semelton500/1815_zpsj9sk9xld.png

Steve Melton

08-17-2019, 01:30 PM

Ready for flight testing a couple angle versions of these. ASA material, UV resistant.

bracket weight = 7 grams
adjustable mirror weight = 20 grams

total 27 grams

selectable version 1500, pitch = 15 deg, yaw =0 deg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1386_zpstwrhrhso.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1385_zpseby98oci.jpg

**
**

selectable version 21-15, pitch = 21 deg, yaw =-15 deg (left)

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1390_zpstvnamyij.jpg

**
**

selectable version 21-15, pitch = 21 deg, yaw =15 deg (right)

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1391_zpsqtsabzun.jpg

**
**

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1392_zps4xovi3fx.jpg

Steve Melton

08-17-2019, 01:50 PM

some carbon fiber fuel cap openers on the bed. lock your fuel caps as tightly as you wish.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1388_zpsdqu4dcoj.jpg

Steve Melton

08-18-2019, 02:51 PM

a couple different angle installed. the angle depends on what you want to see. the mirror is adjustable to +/- 10 degree. the brackets were: 1500, 2115, 21-15. very smoother action on the brackets, easily removable and easy to slide.

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190818_130654_zpsbomgtdq0.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190818_130715_zps5oo4oj1c.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190818_140221_zpsk89iudqy.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190818_140212_zpsr9kzb8lt.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190818_140526_zpsutuqvbfe.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190818_140423_zpsj8wgzbwc.jpg

**
**

Also, if you're into tennis like I am....

Cincinnati Master ATP Tennis tournament - finals: Medvedev vs Goffin. Kings Island on the left side of the highway, sight of the new giga coaster to come.. 300ft high.

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190818_135723_zpsccehu0pz.jpg

Steve Melton

08-19-2019, 06:00 PM

pushing the angles to what we can comfortably do = 33 pitch and 33 yaw. the eye angle is 24 deg for my install. if you wanted to maximize visibility to the left then 33-24 = 9 deg + 10 deg for the adjustable mirror = 19 left and -1 deg range for a 3333 mirror config. and you get a little more because the mirror is also convex. this would also yield more downward view since the pitch is 33. we have printed a 4545 config and it was fully functional but the surface was not as smooth as reduced angle prints.

a 2100 config yields a good range to the right and the tail is clearly visible without excessive view upwards.

it just depends on what one is looking for. it's nice to have options :)

this has been a fun project and I only built one model. the computer did the variations and stamped the config number. this is a good project for someone to try that wants some practice designing and printing and when you are flying with your buddy you can say, hey, I printed that bracket!

https://oi1249.photobucket.com/albums/hh519/semelton500/Eye%20angle_zpsxvwjphr4.png

https://oi1249.photobucket.com/albums/hh519/semelton500/3333_zpssgwljmku.png

**
**

we use this printed drill jig for the holes. what is truly amazing is that the measured distance variation from the side of the rail to edge of the hole in the final drilled part is within 0.002 inch. it does make me wonder if the tool was printed from nylon graphite could I reduce the variation to 0.001 inch. I think it's time to beef up the tool, switch to nylon graphite and go for 0.001 but the real goal in my mind is 0.0005 inch.

https://oi1249.photobucket.com/albums/hh519/semelton500/drill%20jig_zps41q6pf6m.png

Snowflake

08-20-2019, 07:34 AM

we use this printed drill jig for the holes. what is truly amazing is that the measured distance variation from the side of the rail to edge of the hole in the final drilled part is within 0.002 inch. it does make me wonder if the tool was printed from nylon graphite could I reduce the variation to 0.001 inch. I think it's time to beef up the tool, switch to nylon graphite and go for 0.001 but the real goal in my mind is 0.0005 inch.
Steve, why not print the holes? They're just clearance for the locking screw, so even if they don't print perfectly round that shouldn't be a problem... Just print them a few thou larger to compensate?

Steve Melton

08-21-2019, 08:00 PM

Steve, why not print the holes? They're just clearance for the locking screw, so even if they don't print perfectly round that shouldn't be a problem... Just print them a few thou larger to compensate?

the web is thin .122 width with .116 drilled hole leaves .006 or .003 per side. you can't print that thinly at least I can't. if the web breaks thru it is not a problem since the load path is from the larger bar and nut. I went down a rabbet hole to see how tightly I could control the drilled hole with a printed fixture. going down rabbet holes is a pastime of mine. it's turns out so far I can't do better than .002 hole center variation and it depends how you hold you mouth taking the measurement so it could be more. the nylon graphite drill fixture out to be finicky when trying to hold tolerances. the nylon graphite tool looked fine, I just could not get a straight hole reamed thru it, weird. the ASA is much better and we will stay with that material for the drill fixture. however the nylon graphite is noticeably stronger and there is still room for development there.

this is the hole in question that I was trying to make perfectly centered. from a non-uniform printed hole to perfectly round and straight, multiple drill bit and reamer combinations for the tool guide hole did not yield much benefit. there is still room for development for this. perhaps an printed teardrop shaped hole would be beneficial but that is for the future. it's good enough for now and the final parts have a nice smooth action at the thread. fun stuff!

as far as the mirror function goes, I like it. it's not too big or too small. the tail is clearly viewed in the mirror. it's a keeper for me. it's easily removable if it gets in the way. I'm ready to throw this over the wall to Amanda.

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

the first hole is drilled thru from the top side.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1394_zpsylyqqo7j.jpg

*****

punches thru the lower side. this hole is enlarged with the drill fixture at a later operation for the brass plastic nut.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1395_zpsqfjgbfra.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190821_195054_zps1zswnzrl.jpg

Steve Melton

08-24-2019, 09:06 PM

Some experimentation ongoing for drill small diameter holes in parts. Printed in black to be able to see the part details better.

When printing a small horizontal hole a teardrop shape is beneficial. Filling the hole with support material does not lead to a straight hole when drilled. It is better to leave it open and compensate with a teardrop shape design so that the hole is rounder when printed. Note: larger diameter holes track the drill bit better without this teardrop shape compensation.

Teardrop design hole. Hole is printed horizontally with no support material.

https://oi1249.photobucket.com/albums/hh519/semelton500/teardrop%20hole_zpsya7hkr9n.png

**
**

Printed horizontally with no support material. If a teardrop shape is not used the hole will be oval when printed in this horizontal orientation. the oval hole creates forces in drill bit that pull it off center when drilling the softer plastic.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1408_zpsjlzrpt1v.jpg

**
**

Added this teardrop hole feature to the nylon/carbon tooling. Printed one time with teardrop hole feature and it was good. that was the key.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1412_zpsdyr6o0ic.jpg

**
**

Bottom side uses a larger hole for the brass nut.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1417_zps1kgomxpd.jpg

**
**

Top side

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1415_zpsnrddof0a.jpg

**
**

Web thickness = .122 inch. Drilled hole diameter = .114 inch.

.122 - .114 = .006, .006/2 = .003 per side web thickness.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1414_zpsgfgeukay.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1413_zpsqvswagml.jpg

**
**

install a brass plastic nut for the tread and achieve a free spinning thread action thru the part. that's how it's made.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1418_zpsal2ub2jz.jpg

**
**

clearance from thread to edge of the hole = .0015 inch. beautiful.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1419_zpsskgg5ngh.jpg

**
**

three test pieces are boxed for Dave Schuler, the idea man for this design.

carlrai

08-25-2019, 04:01 AM

Steve Melton

08-25-2019, 09:22 PM

Hey Steve,

Just saw this. As always very cool design.

So sitting here Sunday morning with coffee trying to wake up I got to thinking, can you incorporate your Koger feature to accommodate a GoPro mount?
Is carbon filled material strong enough in section to support the camera. Could also be the GoPro Cube which is lighter.

I'm barely awake so this may be either a brilliant or really stupid idea.....

Best

A gopro mounted inside the cabin could be supported with the current mirror mount design and material but the panel would need to be larger. The question is: can the Kroger rail mount adhesive withstand the load. if the rail is mounted well it could probably withstand the load for short periods but I would not recommend leaving it installed on a hot summer day. how large does a gopro panel need to be?

Steve Melton

08-28-2019, 09:59 AM

a full set of 0.75 rudder pedal extensions for both pilot and copilot sides total weight = 182 grams. that's easy on the weight and balance calculation. less than half the weight of equivalent metal, more foot surface area and custom lengths. includes anti-rotation feature.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1421_zpsay8chls4.jpg

Steve Melton

08-29-2019, 01:52 PM

concept 1

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpsgtfci72k.png

**
**

concept 2

https://oi1249.photobucket.com/albums/hh519/semelton500/cap2_zpsv1okewzr.png

**
**

concept 3 - removed convex edges of tangs at ring intersection with fillets -- increased flex capability

https://oi1249.photobucket.com/albums/hh519/semelton500/cap3_zpsn5slauy1.png

**
**

Material = ASA white

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1431_zpsr5nju59g.jpg

Steve Melton

08-31-2019, 01:28 PM

carbon/nylon transition duct for 2 inch dia scat size

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpsauzjfkha.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap2_zpscfuqorly.png

carlrai

08-31-2019, 02:28 PM

A gopro mounted inside the cabin could be supported with the current mirror mount design and material but the panel would need to be larger. The question is: can the Kroger rail mount adhesive withstand the load. if the rail is mounted well it could probably withstand the load for short periods but I would not recommend leaving it installed on a hot summer day. how large does a gopro panel need to be?

I was thinking about my own set up which has the rail screwed in the center support of my slider which now reminds me that the position of the mount would have to be forward to clear the baggage compartment when slid back.
Also, how about reverse engineering the gopro mount itself and incorporate into the Koger fitting.
Happy to send you a mount if you're interested in pursuing.
Again, this all may be half baked until I get back into my RV-9A and confirm all the things I think will work.
On vacation on the beach in Florida. Keeping fingers crossed Dorian stays well east of the mouth of Tampa Bay. Will get my hands on my GoPros and post dimensions and a crude sketch of what I'm thinking about.

Steve Melton

08-31-2019, 02:34 PM

I was thinking about my own set up which has the rail screwed in the center support of my slider which now reminds me that the position of the mount would have to be forward to clear the baggage compartment when slid back.
Also, how about reverse engineering the gopro mount itself and incorporate into the Koger fitting.
Happy to send you a mount if you're interested in pursuing.
Again, this all may be half baked until I get back into my RV-9A and confirm all the things I think will work.
On vacation on the beach in Florida. Keeping fingers crossed Dorian stays well east of the mouth of Tampa Bay. Will get my hands on my GoPros and post dimensions and a crude sketch of what I'm thinking about.

happy to take a look. what about velcro'ng to the camera directly and to the Kroger mirror mount. reverse the mount in the rail to achieve desired angle? that would be the lightest setup. may also be good for training to view inside the cockpit.

Steve Melton

09-04-2019, 08:39 PM

they don't look bad in black

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190904_210623_zpscvfg2d4c.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190904_210647_zpsyipouvt1.jpg

**

**

this machine never gets old to me. it's great!

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190904_212838_zpspdmotgwd.jpg

Steve Melton

09-08-2019, 09:47 AM

Old style Bose AHX control mount concept for my hangar neighbor.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpsnafyuoch.png

**
**

A20 style Bose controller concept.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpsd6trrsor.png

Steve Melton

09-10-2019, 05:07 PM

UV resistant ASA plastic with a .105 inch thick base.

**
**

A20

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpssfey01tw.png

**
**

AHX

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zps7sjmgyju.png

**
**

pre-spaced undrilled holes, if needed, 0.5 inch spacing. my neighbor has both of these controllers and uses clamps on the backside to mount to GlaStar fuselage tubing.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap2_zpsg7xlt9fy.png

Snowflake

09-11-2019, 07:42 AM

This is a great idea. I should make one for my Lightspeed Zulu controller.

Have you thought about a way to retain the controller during unusual attitudes?

ALagonia

09-11-2019, 07:59 AM

I have an A20 and the older I believe X20 Bose headsets. How much for one of your holders for each of my headsets?

Steve Melton

09-11-2019, 07:07 PM

AHX

Aerobatics approved.

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190911_174624_zps35pygcuf.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190911_174710_zpselbiccom.jpg

Snowflake

09-12-2019, 07:24 AM

AHX

Aerobatics approved.
Neat! Is that just a friction fit, or do you key into a feature on the control unit to lock it there?

Steve Melton

09-12-2019, 02:04 PM

Neat! Is that just a friction fit, or do you key into a feature on the control unit to lock it there?

The AHX control module is a tube shape so light friction on the side will keep in in place when turned upside down. The A20 control module is more of a wedge shape and is not held by friction. It just makes very light contact with the edges and will release when turned upside down. The clearance on the side of the A20 is for a press volume control button.

A20

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1462_zpsmolatt8x.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1453_zps0wzibrni.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1452_zpsnrhqxfn9.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1449_zpsryqwfoqg.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1446_zpsus7grbqo.jpg

FlyingBanker

09-13-2019, 08:19 AM

Steve, are these A20 holders available for sale? I don't see them on your website.

Steve Melton

09-13-2019, 09:33 AM

Steve, are these A20 holders available for sale? I don't see them on your website.

Amanda will upload them by this weekend. We became consumed last night trying to join copper, nickel and silver for a metals art class project.

And also, if anyone needs a different control module mount developed, send Amanda your headset and we will make you one for free and return it to you in a week. This has been a good training project for Amanda using lofting and she's got it now and can churn them out.

We currently have:
A20
AHX-32-01

Bill Boyd

09-13-2019, 12:09 PM

cderk

09-13-2019, 04:02 PM

Steve, have you thought about doing an intake bell mouth for the SCAT connections on the rear baffles, for heat and oil cooler air? Those square shoulders on the VA-187 can't be good for maximizing air flow.

How about your own version of rear baffle hole covers where the Lord mounts protrude through?

I'm sure I can lay this stuff up over clay plugs with lightweight cloth and epoxy, but it seems like a natural application for 3D printing in appropriate material.

Now that you mention intakes on SCAT tubes, a bug screen holder that you can slide in there would be nice too. I guess the user would have to supply their own material. There is a write up in the July2018 Sport Aviation magazine that shows how to make one using 2? tubing. I was thinking of something like this for the -10 to keep out the bees :)

Steve Melton

09-14-2019, 06:54 AM

Steve, have you thought about doing an intake bell mouth for the SCAT connections on the rear baffles, for heat and oil cooler air? Those square shoulders on the VA-187 can't be good for maximizing air flow.

How about your own version of rear baffle hole covers where the Lord mounts protrude through?

I'm sure I can lay this stuff up over clay plugs with lightweight cloth and epoxy, but it seems like a natural application for 3D printing in appropriate material.

I've thought about it but the temperatures under the cowl are too high for ABS and ASA. I am planning to experiment with graphite/nylon to understand it's temperature capability. The filament I have has a Tg of 147C and you want operate 25C below that so that's 122C (250F)max. The next part I am planning for is the spark plug lead pass thru wire mount to test on my aircraft. Peak soak back maximum temperatures usually occur at around 6 minutes after shutdown so I will be able to connect a thermocouple to the parts and check after landing.

Steve Melton

09-15-2019, 07:01 AM

I'm sure these will make someone happy.

https://i1249.photobucket.com/albums/hh519/semelton500/DSCN1518_zps62c8otxi.jpg

Steve Melton

09-17-2019, 05:29 AM

max reading = 208F at 8 minutes after shutdown on a 75 degree day. if ambient temperature was higher the reading would obviously be higher. I'll try to find my ambient temperature correction equation but for now I'll just add the delta to 115F day of 115-75 = 40. So, 208 + 40 = 248F. That just just under the 250F max operating temp for my graphite/nylon (-25C of the nylon Tg), so I'll proceed with the spark plug lead pass through grommet. note: under cowl engine temperatures can vary depending on the engine. my engine is 0-320 with a standard oil cooler. PLA, ABS or ASA material does not have sufficient temp capability for this location.

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190915_180442_zpsst11mjgd.jpg

to look something like this

https://www.aircraftspruce.com/catalog/graphics/08-06133.jpg

Bill Boyd

09-17-2019, 09:01 AM

Now do the -540 (3 holes):D

Steve Melton

09-18-2019, 09:36 PM

thinking of this design and how best to print..... kicking it around.

https://i1249.photobucket.com/albums/hh519/semelton500/cap1_zpspqogazck.png

Snowflake

09-19-2019, 07:52 AM

Make it in three pieces... Make the two halves for the cable holders, but put a flange around the outside that would sit on the baffle. Those pieces can be printed with the split plane (through the center holes) on the print bed. Make a third piece for the mounting flange, that fits around the cable holders, but has a recess to fit around the flange as well. Print that with the front (face we're looking at in your photo) on the bed. The recess won't need supports that way. It will also allow the cable holders to "float" a little bit, which may help with alignment/installation.

Steve Melton

09-19-2019, 05:43 PM

Three pieces is a thought but prefer to be minimum parts. I'll try this and see how it goes with carbon/nylon, two pieces. They are mirror pieces like the Slick but the pins are not mirrored. I'll print a couple of these to determine if it is possible and if so, then tweak it to close the gaps.

https://i1249.photobucket.com/albums/hh519/semelton500/cap1_zpsu1m4w5w3.png

https://i1249.photobucket.com/albums/hh519/semelton500/cap2_zpsm2kvzbqf.png

https://i1249.photobucket.com/albums/hh519/semelton500/cap3_zpsi9wzkm3w.png

**
**

carbon/nylon

first print, some work to do but encouraging.

https://i1249.photobucket.com/albums/hh519/semelton500/DSCN1543_zpss7yp94xx.jpg

Steve Melton

09-20-2019, 04:52 PM

Amanda worked up an idea for a gust lock pouch and Abby at FlightLine Interiors did a prototype in Army green nylon/canvas. It has a semi-rigid bottom and individual spaces for each gust lock piece. This should reduce the rope tangling issue. I will get some pictures of it in the plane. It should tuck between the passenger seat and the fuselage and slide back some and be out of the way but easy to retrieve. It's not final, send Amanda a comment if you can think of anything better with it. My wife has already made some comment about preferring a zipper.... Maybe the handle should be on the end instead of the top?

https://i1249.photobucket.com/albums/hh519/semelton500/DSCN1544_zpsrjgrg0r6.jpg

https://i1249.photobucket.com/albums/hh519/semelton500/DSCN1547_zpsspcszfoc.jpg

https://i1249.photobucket.com/albums/hh519/semelton500/DSCN1548_zps9myceimg.jpg

https://i1249.photobucket.com/albums/hh519/semelton500/DSCN1550_zpsodhdusix.jpg

https://i1249.photobucket.com/albums/hh519/semelton500/DSCN1551_zps8wxxttxp.jpg

Snowflake

09-21-2019, 08:25 AM

sahrens

09-21-2019, 04:06 PM

I'm sure these will make someone happy.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1518_zps62c8otxi.jpg

Any chance of getting something like this for Lightspeed Zulu 3 headsets?

RV8JD

09-21-2019, 04:44 PM

Any chance of getting something like this for Lightspeed Zulu 3 headsets?

Sporty's has them:

https://www.sportys.com/pilotshop/catalogsearch/result/?q=control+box+holder

scard

09-21-2019, 04:57 PM

Wow, I didn't realize that headset control box "holder" was a thing. All those batteries and such must be quite the burden :).

rocketman1988

09-21-2019, 05:44 PM

Can?t stand in ear headsets, not the least bit comfortable, for me. I will keep my batteries...:D

Steve Melton

09-21-2019, 05:46 PM

Any chance of getting something like this for Lightspeed Zulu 3 headsets?

currently we only have Bose A20 and AHX. send Amanda your headset for a week and we will make you a couple of them in order to have a pattern. we will return everything at no charge.

Steve Melton

09-21-2019, 05:50 PM

Hey, that's really neat! It looks like it could be made even smaller though... I see a fair bit of empty space around the rope and in the two pockets on the left end in the open view. Building on the "beside the passenger seat" thought, what if it were shaped to fit the seat pan on the bottom? Then it would fit down and back mostly out of the way?

I wonder if Velcro would last longer than a zipper. Maybe it depends on how often it gets used? I know Velcro tends to clog after a while and become less effective.

yep, I think it could be 1/2 inch narrower. it tucks well beside the seat and slides back out of the way. that part is good. we need to investigate a zipper vs velcro. so far, I like it. I'll fly with it for awhile. I'll get some photos loaded by tomorrow.

Steve Melton

09-22-2019, 08:30 PM

I think this completes all the RV's at HAO. Final rope adjustments to be made by the owner. the gap on the left hand side horizontal stab was just enough. he doesn't have to worry about his rudder anymore.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1596_zps4ezr8xbf.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1597_zpsjeex6aww.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1598_zpscaonqx6y.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1599_zpsvac8imyq.jpg

good arm muscles, now get back to work

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1600_zpsudbfcnck.jpg

Steve Melton

09-22-2019, 08:40 PM

in the cockpit. compliant, it will not stab you in the heart.

https://i1249.photobucket.com/albums/hh519/semelton500/DSCN1552_zpsfyjt5w7k.jpg

https://i1249.photobucket.com/albums/hh519/semelton500/DSCN1555_zpsvh6imn4y.jpg

https://i1249.photobucket.com/albums/hh519/semelton500/DSCN1557_zpscolpwslf.jpg

Steve Melton

09-26-2019, 07:05 AM

Carbon/nylon

First one off the line as printed. Needs some adjustment but I am confident it is going to be a nice fit. Lays flat on the back to within .002 inch when nested. Right side holes need to be reduced for .275 clean up. I am looking forward to installing it.

https://i1249.photobucket.com/albums/hh519/semelton500/DSCN1602_zpsjc0cblna.jpg

Snowflake

09-27-2019, 08:05 AM

FYI - Your pictures aren't loading this AM, Steve... The last three posts show as text-only.

Sam Staton

09-27-2019, 06:29 PM

https://www.flickr.com/gp/184713614@N06/GtX4Gy

Wiring loom
My images are not showing either - using Flickr

Steve Melton

09-29-2019, 06:05 PM

FYI - Your pictures aren't loading this AM, Steve... The last three posts show as text-only.

yeah, Photobucket heads. I reposted the spark plug pass thru.

Snowflake

09-30-2019, 07:49 AM

yeah, Photobucket heads. I reposted the spark plug pass thru.

Still nothing this AM. Maybe you should move the images to your rvplasticparts website and link to them there?

Steve Melton

09-30-2019, 09:54 AM

Still nothing this AM. Maybe you should move the images to your rvplasticparts website and link to them there?

I'll give them some time to fix it. I upgraded to their pro because of increased data flow. If they can't fix it then I'll move to rvplasticparts.com.

********

Photobucket response: The issue you are seeing is due to the "o" added to your image url. The "o" directs the image link to the original size of the image.

Unfortunately, linking the image directly to its original size is no longer supported as this makes the images display larger on other websites. You can fix this issue by removing the "o" from your image url. The image links in your account also do not have the "o" added to them.

********

someone is always changing something.

********

this one is to be installed. not the most beautiful part but very tough. hopefully, I will find some method to improve part finish.

https://i1249.photobucket.com/albums/hh519/semelton500/DSCN1603_zpsyfekivtc.jpg

Steve Melton

09-30-2019, 05:05 PM

Jabara airport called me and said there are thunderstorms inbound do you want us to move your plane inside. Nope, it will be fine since it's chained and low chance for hail. When I picked it up the chains were tight and aircraft was rotated into them and everything was fine. Jabara's charge for moving the plane inside is $75 per night and I didn't take them up on it. My total charge from them for 16 gallons and 3 nights tie down was $125.

A couple of photos of when I tied it up. It was the same when I departed. I really like Amanda's gust lock pouch. No tangles. All the pieces are stored and good to go.

https://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190927_173638_zpsnysq8ige.jpg

https://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190927_173645_zpsrxcwse1p.jpg

https://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190929_103058_zpscfmiu1l5.jpg

**
**

7.5K climbing to 11.5K, Wichita to Cincy, 605 nm, 22 gallons total. average tailwind = 20 kt. MP = 19.8, prop 2200 RPM, 1 or 2 degrees pitch until some fuel burns off, lean of peak, everything is running cool. OAT = 9C @ 11.5K. warm day.

https://i1249.photobucket.com/albums/hh519/semelton500/IMG_20190929_111038_zpshms0ihkf.jpg

Snowflake

10-01-2019, 07:43 AM

Nice photos, looks like a great trip! Confirmed, they are working again this AM.

Vlad

10-01-2019, 09:06 AM

Steve Melton

10-01-2019, 10:13 AM

Steve let us know when these are available. My buddy needs one yesterday :)

send me his name and address and Amanda will see that he gets a couple for "testing".

Vlad

10-01-2019, 11:59 AM

send me his name and address and Amanda will see that he gets a couple for "testing".

PM on the way Steve. Address and phone # included thanks.

Steve Melton

10-02-2019, 07:00 AM

Arizona should be a good place for testing these.

https://i1249.photobucket.com/albums/hh519/semelton500/DSCN1604_zpser8pzura.jpg

WingsOnWheels

10-02-2019, 02:23 PM

Probably something like this already burried in this thread, but I made my own gust lock.

https://i.postimg.cc/9fxJvjZY/20190927-095417.jpg

Steve Melton

10-02-2019, 04:32 PM

we have no fear of 87 kt ground winds and above that we still feel pretty good because we have stress margin. let it blow. RV7 rudder gust lock printing now.

https://i1249.photobucket.com/albums/hh519/semelton500/DSCN1611_zpstjif5thj.jpg

David Paule

10-05-2019, 05:33 PM

I'm probably jumping the gun with this and if so I apologize.

For those of you using Gil Alexander's excellent Dynon network hub kit, described in this thread, (http://www.vansairforce.com/community/showthread.php?t=158674) what it needed was a stand-off base that kept the traces off the mounting surface and protected them against scrap. This is that part.

I'd asked Steve to see what he could do, and with a sketch of mine he designed this handy stand-off. It fits the #6 screws that the hub mounts with and doesn't interfere with anything. Here it is:

https://i.imgur.com/ZPZYKmt.jpg

And in use, the finished hub and this part work like this:

https://i.imgur.com/PGbCgyp.jpg

You'll have to contact Steve or Amanda for the parts; I'm merely the guinea pig they tested it with. The photos show a prototype. In fact, the screws I used for the fit-up are the screws that I had handy. They aren't the flight screws.

Thanks Steve, and thanks, Amanda. Got to say the production and design departments here are all good - and I'm including Gil in that, too.

Dave

Steve Melton

10-06-2019, 10:31 AM

final design. I was able to clean it up some but it's not pretty but should be functional if max temperature < 250F. For my engine, for 115F day, max temp should be ~ 250F. The Tg for this nylon material = 296F, so there is some margin for material variation.

https://i1249.photobucket.com/albums/hh519/semelton500/DSCN1615_zpsdbshn68r.jpg

https://i1249.photobucket.com/albums/hh519/semelton500/DSCN1614_zpsghqxo08r.jpg

https://i1249.photobucket.com/albums/hh519/semelton500/DSCN1613_zpswjgge7o7.jpg

Steve Melton

10-06-2019, 07:30 PM

the previous pass thru was small and required some additional covers. the printed version covers all of it.

https://i1249.photobucket.com/albums/hh519/semelton500/IMG_20191006_173321_zpsqwjmhfbo.jpg

https://i1249.photobucket.com/albums/hh519/semelton500/IMG_20191006_182937_zpsrjf0ufh8.jpg

https://i1249.photobucket.com/albums/hh519/semelton500/IMG_20191006_183007_zpsswxzkcny.jpg

https://i1249.photobucket.com/albums/hh519/semelton500/IMG_20191006_183036_zpsi3nnzrwl.jpg

Steve Melton

10-07-2019, 09:09 PM

0.1 inch thick x 0.5 inch wide strip baked at 250F, 260F, 270F, 280F, 290F, 300F over 3 hrs. temperature verified by IR.

250F

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1624_zpsd9q5sau3.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1623_zpsygb3tamt.jpg

**
**

300F

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1638_zpsfvfucyae.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1634_zpsglq9upzs.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1642_zpsqcv2h3xl.jpg

Steve Melton

10-09-2019, 06:22 AM

within the same space as two hole version, a third hole added. max operating temperature = 250F

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1643_zpseobrnktt.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1645_zpsndorwlam.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1648_zpsuajz9ys2.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1653_zpsu1lefjcb.jpg

Steve Melton

10-13-2019, 08:15 AM

fitting a mount to the Clarity Aloft. thx for sending it in. it will be returned within a week with a couple mounts.

UV resistant ASA material.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1662_zpswmao4jlr.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1664_zps62hkgq2q.jpg

Steve Melton

10-13-2019, 04:20 PM

after a couple flights I inspected the copilot side. I noticed a slight loss of torque on the screws. This is normal for composite parts under heat load. Usually one re-torque is needed. I'll check again after a couple flights for any loss of torque.

Installed the pilot side.

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20191013_160134_zps3r8dfh1t.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20191013_163152_zps1eqsuy4r.jpg

Steve Melton

10-14-2019, 03:29 PM

on the way back to the owner after 4 days with a couple free control mounts.

thx for the use of your headset for a pattern. you will like the fit.

so far we have:
Bose AHX
Bose A20
Clarity Aloft

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1665_zpswn5slibk.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1675_zpsipojszko.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1687_zps2qpfcui9.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1689_zpsz57kayil.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1694_zpsp52rm6vs.jpg

Sam Staton

10-14-2019, 04:37 PM

You’re welcome. Looks good.

Steve Melton

10-14-2019, 08:42 PM

Drill Pattern

https://oi1249.photobucket.com/albums/hh519/semelton500/drill%20pattern_zpsuccdlrpu.png

flysrv10

10-15-2019, 06:17 AM

Steve, looking to buy an aileron gust luck for RV10. No response from rvplastics. Three messages on rvplastics website looking to do the same. Thanks.

Steve Melton

10-15-2019, 06:22 AM

Steve, looking to buy an aileron gust luck for RV10. No response from rvplastics. Three messages on rvplastics website looking to do the same. Thanks.

I don't think Amanda is notified of questions on her website for product comments. Just send her an email.

flysrv10

10-15-2019, 06:25 AM

Have sent her direct email too. perhaps I have the wrong email.

Steve Melton

10-15-2019, 06:32 AM

Have sent her direct email too. perhaps I have the wrong email.

I'll check with her. One of the nice aspects of working these plastic parts with Amanda is that we communicate more than we would otherwise.

Steve Melton

10-15-2019, 09:36 PM

a nice tactile feel material. stiff, lightweight, and beautiful. relatively quick to print.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1719_zpsqlr99fty.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1721_zpsapgzbvpv.jpg

Steve Melton

10-16-2019, 04:21 PM

similar feel to carbon but not the same. lightweight and stiff.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1724_zpsvqtywv1e.jpg

Steve Melton

10-20-2019, 07:21 PM

checked the torque on the copilot side and it was OK. it had one re-torque since installation. re-torqued the pilot side for the first time, it had lost some torque since the install. I'll check the torque again at the next oil change in 50 hrs.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1774_zps5jhgkcpi.jpg

Steve Melton

10-26-2019, 06:19 PM

Prop pitch angle tool

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpslfkahcip.png

Vlad

11-02-2019, 04:55 PM

Fairlead pair installed on a project in Arizona.

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

Another set is flying in New Jersey 15 hours +

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

A lot of those needed :D

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

Steve Melton

11-11-2019, 08:55 AM

Vlad, I noticed you use a bigger head screw. That's the right approach for these. I followed your lead.

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20191110_145655_zpsyvc68apf.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20191110_143524_zpsjafexbx9.jpg

Steve Melton

11-11-2019, 08:57 AM

LightSpeed Zulu3 headset controller mount in progress.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpswfoa22yl.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap2_zpsmyjr8dte.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap3_zpswqwolebr.png

**

one of the best complex corners I have made.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpsfaul0k6i.png

Steve Melton

11-12-2019, 02:27 AM

This headset goes back to the owner tomorrow. A record two day turnaround. It is a very good fit. Approved for aerobatics but easy to remove. I like it and I know the owner will too.

Note for printed parts: when you see some stitching marks on a flat surface at the perimeter edges you know the previous layer is overlapped at the edge with the current layer by some amount. this stitches the edges together to form a superior bond. the stitching marks typically fade away from the edges. I always look for this on on the flat surfaces of printed parts.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1790_zpslk7wzphv.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1792_zpsckzochig.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1797_zpssha7vwys.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1798_zpsw0k8o2xy.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1795_zpsox4e4ecp.jpg

Steve Melton

11-13-2019, 05:23 PM

Kicking around a concept for simple fuel sump tester mount. I think I would test more frequently if the tester was easier to access.

A beginning concept.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpsgbfrwvj1.png

**

taking a look at bending stress in the retainer. plan to mathematically determine the optimum beam taper for uniform bending stress as a fun endeavor. MATLAB will be used to help with this.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap4_zpsghandak7.png

**
**

this is looking good from a stress perspective. the key is to allow the bottom plate to flex and do some bending. spread the load with a big asymmetrical fillet that essentially creates an elliptical shape. I also blended the lateral restraint pocket to act as a guide.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap5_zps11gpeukp.png

**
**

I like it. I'll install it for testing. Weight is only 30 grams. ASA plastic, UV resistant. secure but easy to remove. anti-rotation feature. attach with velcro. it should have a long life. plate is recessed to fit cap end but will accept testers with no cap end. mount it vertically and it would serve to be a good location for gasohol testers that require a 10 minute wait time.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1809_zps1uqt5tjh.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1812_zpsfrgeubct.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpswvy07o6h.png

**
**

installed. I like it. the only thing better could be a funnel fit at the tip for returning the tester to the mount. since it is a blind return for me a funnel fit at the tip would be beneficial. I'll see what I can do. installed with duel lock velcro. this sump tester is literally at my fingertips. no more excuses for sumping the tanks. Master Sargent Ray Parker is in to have a look. I stand as straightly as I can. Ray sumps his tanks at every fill.

**
**

new lower pocket for ease of finding in the dark. just get it close and it will find the home. some complicated geometry in there, amazing.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap2_zpszkliapox.png

**
**

a nice part

https://oi1249.photobucket.com/albums/hh519/semelton500/cap3_zpswf27fcjc.png

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1813_zps9qtfnytu.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1816_zpsppciwazz.jpg

Steve Melton

11-15-2019, 07:56 PM

Snowflake

11-16-2019, 08:50 AM

very early stages of a Lycoming crankshaft.

You'll print that using ABS, or Nylon? Got a TBO estimate yet? :cool:

Steve Melton

11-16-2019, 10:15 AM

You'll print that using ABS, or Nylon? Got a TBO estimate yet? :cool:

TBO = 0 cycles :)

to be used as an analysis model to understand the torsional response with prop mass inertia. it is slow process to make this model but making some headway.

on a side note: I shipped the first RVPlasticParts without leaving the home. USPS Printed labels and tracking, boom done! Life can begin to return to normal for me.

Steve Melton

11-16-2019, 03:36 PM

LightSpeed Tango control module. Needs to fit with cover on. I'll give it a try.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1808_zps2dovlipn.jpg

Steve Melton

11-19-2019, 02:48 PM

one of our rudder pedal extensions ABS (grey) and ABS/Carbon (black) for a strength test. ABS/Carbon is stiffer by feel. Material test data states the ABS/Carbon is stronger but the the only way to truly know is to test the actual part.

weight ABS (grey) = 25 grams
weight ABS/Carbon Fiber (black) = 24 grams ( but double checking this the ABS/Carbon Fiber extension is .120 inch longer, so on an equal basis it is lighter by another couple of grams. )

always use a hardened steel nozzle to print Carbon Fiber because of nozzle wear

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1818_zpsuo9dds0n.png

**
**

my arrangement for the past year. cushion for the pilot, round for the copilot.

it looks like I need to flush my brake lines. they are turning blue. that's 800 flight hrs worth.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1831_zps3g8yrepv.jpg

Steve Melton

11-19-2019, 07:23 PM

I like it to be convenient and secure.

on the wall
https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1824_zpsiug8we6d.jpg

**
**
in the cockpit
https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1826_zpsskf5ewvf.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1830_zpstv7rgyxk.jpg

**
**

highly recommend 3M Dual Lock Velcro

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1820_zpsqwwru6la.jpg

RVDan

11-19-2019, 07:52 PM

TBO = 0 cycles :)

to be used as an analysis model to understand the torsional response with prop mass inertia. it is slow process to make this model but making some headway.

on a side note: I shipped the first RVPlasticParts without leaving the home. USPS Printed labels and tracking, boom done! Life can begin to return to normal for me.

If you collect payment via paypal, you can use their discounted postage to print a label and ship.

Steve Melton

11-19-2019, 08:44 PM

If you collect payment via paypal, you can use their discounted postage to print a label and ship.

copy that, thx. whatever I do, I have to keep it as simple as possible.

Snowflake

11-20-2019, 07:56 AM

copy that, thx. whatever I do, I have to keep it as simple as possible.

I know you've already got the printers now, but have you considered moving to a vendor like Shapeways, that will do the printing for you, handle the shipping, and take a percentage? Shapeways at least can offer a lot more options for printing... SLA/SLS, and I think they'd even do a urethane mold for a small volume of injection molded parts.

That way you could do all the prototyping at home, then just upload the finished product to their site and direct people there to order. You wouldn't have to deal with printing or shipping.

D Weisgerber

11-20-2019, 02:36 PM

I just got 2 mounts for my Light Speed control module. The shipping was fast and the units worked very well. It was listed as Zulu 3 control module mount, but it worked perfectly with my Zulu 2. Thanks.

Steve Melton

11-20-2019, 03:23 PM

Vlad

11-20-2019, 04:23 PM

Steve the flap hinge covers are still there. :D

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

Steve Melton

11-20-2019, 04:27 PM

hanging on at the edge of the canyon! I too am feeling the pull to head West.

Steve Melton

11-20-2019, 04:53 PM

I know you've already got the printers now, but have you considered moving to a vendor like Shapeways, that will do the printing for you, handle the shipping, and take a percentage? Shapeways at least can offer a lot more options for printing... SLA/SLS, and I think they'd even do a urethane mold for a small volume of injection molded parts.

That way you could do all the prototyping at home, then just upload the finished product to their site and direct people there to order. You wouldn't have to deal with printing or shipping.

I would be concerned about quality. Printing technology is still new and while our hardware is not flight critical it is still for flight and that raises the bar. Also, I like to hear the printers operating. :) but far into the future it could be an option to make sure the parts are still available. thx for the thoughts.

Steve Melton

11-24-2019, 08:43 AM

Lightspeed Tango Control Module Mount. Control module is going back to the owner today. I'm sure he will like the fit.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1867_zpsjftyymai.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1869_zpsnljsbeab.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1871_zpsqrehknf2.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1872_zpsfc78nk8x.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1875_zpswivnz0p7.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1865_zpselayx3y3.jpg

Steve Melton

11-26-2019, 03:11 PM

very early stages of a Lycoming crankshaft.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpsgbxi4cka.png

**
**

some headway for the base structure

https://oi1249.photobucket.com/albums/hh519/semelton500/cap2_zpse6l7iqep.png

**
**

slogging along....

crank_no pistons_no prop_no sludge tubes

1st freq = 1100 Hz (good and stiff)

https://oi1249.photobucket.com/albums/hh519/semelton500/frequency_zps9bzu1af6.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zps2m1nbzmh.png

F1 Rocket

11-26-2019, 05:50 PM

Hi Steve,

Would you happen to have a design for a Dynon D3 Mount? I?m looking for a clean way to mount it off the front seat back tube in my Rocket.

Danny

Steve Melton

11-26-2019, 06:00 PM

let's think about that. I have a D2 mounted that needs more angle. It is currently installed with 3M dual lock velco and has been very secure. If it is angled upwards it would need slide in from the side, correct?

EDIT: I remember now and see it in my photo that the Dynon has a clip in feature so it just needs angle support. the angle support could be attached by screws or maybe even dual lock. screws would be more secure.

and you see that piece of paper with green tape on the pilot side. those are my V-speeds. wouldn't it be nice to have better looking place for those. when my wife sees tape on the airplane she says "so, that's what's holding it together?"

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190821_203049_zpslyz6b3we.jpg

Steve Melton

11-27-2019, 03:56 PM

how about something along this line. the hole placement is not final as I have no accurate dimensions. set to #8 screws.

selected the angle you want. it may even work with dual lock velcro if you didn't wish to drill holes.

we could possibly reverse the outermost screw direction to have the screw head be to the backside of the seat and nest the nuts in the mount. give me some input.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpsruvimgir.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap2_zpscjk3lfhg.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap3_zpsn8ypvhia.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap4_zpscarragis.png

F1 Rocket

11-27-2019, 06:23 PM

I’d like to clamp the mount to the tube that the front seat back leans against. The angle would be more or less infinitely adjustable.

Steve Melton

11-27-2019, 07:53 PM

OK, I'll take a look at it the next chance I get to view an RV8 to see if there is anything I could do. I'll go ahead and finish this angle version since I need it.

Steve Melton

11-27-2019, 08:45 PM

concept for a card holder. weight = 40 grams. I think I can get it down to 30 with added lightening holes and some other changes.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zps9uh62fj0.png

**
**

down to 33 grams

https://oi1249.photobucket.com/albums/hh519/semelton500/cap2_zps2ngxzhjq.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap3_zpsjmqgwqsw.png

**
**

I didn't really like this part at first but it is beginning to grow on me. I'll take a look at it in the cockpit.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap4_zps5mlxte2j.png

**
**

https://oi1249.photobucket.com/albums/hh519/semelton500/20191128_092922_zps1zcs1zli.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/20191128_092944_zps4q6pkxmu.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/20191128_093003_zpsaota766y.jpg

Snowflake

11-28-2019, 07:47 AM

Steve, maybe take a look at what McMaster has for threaded inserts for plastic (https://www.mcmaster.com/threaded-inserts-for-plastic). I use the "press-fit inserts for plastic" as they have larger teeth on them, but I still set them in place using a soldering iron. The flanged ones inserted from the back are incredibly strong and won't pull through. Saves having to put a nut in the backside (or rather, saves having a nut fall out and down into the belly of the plane).

Steve Melton

11-28-2019, 07:49 AM

Steve Melton

11-29-2019, 07:37 PM

the plan is to replace my taped on V-Speeds with something more elegant and it should be very light weight and hold a couple of cards for notes. I choose a 3 x 5 card size since that is common and about the same size as what I have. the nice thing about the taped on paper version is that I can swing it out to have a better look and I wanted to retain that function. I believe the loose strand velcro will work fine for this. yet to be tested. I've been working on getting the weight to the absolute minimum for this piece. I'm down to 27 grams (exceeded my goal of 30) using no internal printing support. the challenge you face with this is printing a slightly angled round hole in a vertical orientation when there is no support is the filament sags away at the top. one way I have managed to counter act this is to shape the hole as a teardrop. this part is hollow.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap8_zpsgjalivoa.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap7_zpsblku209u.png

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1905_zpstvqklnhr.png

Steve Melton

11-29-2019, 08:25 PM

hey, you have to begin somewhere..... this is going to be a long road.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1901_zpshfy3fcwg.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1900_zpszyvxjxuq.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1902_zpsirjufzdl.jpg

Steve Melton

11-30-2019, 03:56 PM

the fit and the velcro swing action was good. one thing I will change is to drop the card retainer sides to ease card removal. other than that I really like it. it's a keeper. I'll also make one with no holes that could be preferred for a solid writing surface.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1910_zps23gyfmde.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1911_zpsl9te1yn0.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1913_zpsrslvtwfc.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1918_zpsp4efq5tx.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1921_zps5qfnwq0q.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1917_zpsta4odld8.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1923_zps69dikykk.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1928_zpsimewpeyv.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/cap9_zpszyixugjt.png

Steve Melton

12-01-2019, 09:33 AM

These can be made to custom angles. This one is 15 degree. Weight = 57 grams.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1932_zpspzeiyp3m.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1934_zpshe6htxp4.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/cap5_zpsej4cw6sv.png

Steve Melton

12-01-2019, 07:10 PM

Prototype installed

this should correct the visibility problem my passengers had trying to view the Dynon when mounted flat. a couple of changes are needed. one, I need to slightly adjust the plastic nut position, two, I will cut about a quarter inch off the top since it's not needed. the force to remove this from the the dura lock was about 30 lb. it's very secure and that's the way I will leave it. this dura lock it rated to 250F if you beleive that.

this one is good enough to stay onboard. I like it. that's the way it should have been from the beginning.

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20191201_172406_zpsqkk7osli.jpg

**
**

the velcro could have been moved more inwards to be out of sight but I was too lazy to reposition it on the panel.

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20191201_172540_zpsc2hbmbfi.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20191201_173535_zpstwp9j0ea.jpg

Steve Melton

12-02-2019, 03:30 PM

Bill is the inventor of the plastic block drill guide and slider canopy install procedure. It seems he likes this method. He said the pin holes align perfectly and he sent some pictures so I thought I would pass them along. He has built several sliders.

His words "Best fitting canopy yet, the blocks are great, pins slide in perfectly."

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_7043_zpsdgepoclf.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_7042_zpsiuoq05fd.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_7041_zpsehjbb9cq.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_7040_zpsfniswwdl.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/RV7-9%20Slider%20Canopy%20Block%20Drill%20Guide%201_zp smxwuy2kx.png

rv8ch

12-03-2019, 11:19 AM

Has anyone ever printed one of these?

https://www.prusaprinters.org/prints/7349-lycoming-oil-dipstick-adapter-plug

https://media.prusaprinters.org/thumbs/inside/1280x960/media/prints/7349/images/54499_e42b8f24-b63e-4d86-a369-1487270a5bbe/oil_plug.jpg

Steve Melton

12-03-2019, 02:19 PM

it's doable. this is a relatively course thread print but it turned out better than I expected. the threads would need to be polished before use.

from a couple years ago.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN0637_zps3dseebt5.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_1480%20copy_zpsuoqkyhrf.jpg

Steve Melton

12-05-2019, 04:38 AM

For 6 inch test tube barrels. Overall length of test = 8 inch. For the ASA model. UV resistant plastic.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1976_zps1blhlpwq.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1970_zpsxiuns4bl.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1968_zpsoagkxblm.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1967_zpst7agyqg6.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN1965_zpsdxufnfso.jpg

Steve Melton

12-13-2019, 06:41 PM

my first 200 HP cruise prop airfoil section

needs a lot of work to make functional... it's a long term project

https://oi1249.photobucket.com/albums/hh519/semelton500/cap2_zpskuzzi3tf.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpszfbegmww.png

**
**

1/4 scale on the printer. nice to be able to hold in the hand within 2.5 hrs.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap3_zpsfrklisvg.png

**
**

recording the zebra stripes before hacking at it.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap4_zpsyot0vbfl.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap5_zpswpq5rpww.png

NTex

12-14-2019, 11:40 AM

it's doable. this is a relatively course thread print but it turned out better than I expected. the threads would need to be polished before use.

from a couple years ago.

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_1480%20copy_zpsuoqkyhrf.jpg

Steve,

I like this optical magnifier thing... what is it?

Thanks
Chris

GWZ

12-14-2019, 02:24 PM

[QUOTE=rv8ch;1390473]Has anyone ever printed one of these?

First off, thanks for the link! I had gathered all the parts for the DIY crankcase air dryer but never put it together. This will get me back on track.
I just printed these on a Ender5 and they came out perfect. I haven?t tried to thread the cap on to the dipstick tube but the threads look clean so I expect no problems.

Steve Melton

12-14-2019, 02:58 PM

Steve,

I like this optical magnifier thing... what is it?

Thanks
Chris

that's an optical comparator.

rv8ch

12-14-2019, 11:55 PM

First off, thanks for the link! I had gathered all the parts for the DIY crankcase air dryer but never put it together. This will get me back on track.
I just printed these on a Ender5 and they came out perfect. I haven?t tried to thread the cap on to the dipstick tube but the threads look clean so I expect no problems.Cool - let me know if it works. I'll try to find a printing shop to do it for me. I'm currently putting the air dryer in the breather, but I guess after the engine has been run a while that will be pretty messy. Anyone have any recommendations for a good 3d print shop that can take a drawing like this and produce a usable part? I've seen dozens in my google search, but not sure which one to choose. Thanks!

N941WR

12-15-2019, 06:51 AM

GWZ

12-15-2019, 10:27 AM

“Cool - let me know if it works. I'll try to find a printing shop to do it for me. “

Will do. Any 3d printing services that are available to you in Switzerland would probably work ok. The Ender line of printers are considered entry level so if they can print this cap then anyone in the business of 3D printing should do even better. I’d pick the least expensive.
Edit: I think the page you linked to has options to buy it printed? Or for less than $200 USD you could buy a Ender3 and make any number of doo-dads to your heart’s content.

rv8ch

12-15-2019, 02:03 PM

?Cool - let me know if it works. I'll try to find a printing shop to do it for me. ?

Will do. Any 3d printing services that are available to you in Switzerland would probably work ok. The Ender line of printers are considered entry level so if they can print this cap then anyone in the business of 3D printing should do even better. I?d pick the least expensive.
Edit: I think the page you linked to has options to buy it printed? Or for less than $200 USD you could buy a Ender3 and make any number of doo-dads to your heart?s content.Thanks - I will be buying a 3d printer, but the last thing I need now is another cool toy - gotta get my RV-8 finished and flying first! :D

Steve Melton

12-17-2019, 07:27 AM

mockup of a prop about 1/3 scale

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2006_zps8gfqnffc.jpg

Steve Melton

12-17-2019, 01:01 PM

any interest in a cowl winter kit to block some air flow? I'm kicking this idea around at a request but not sure how best to attach. material could be high temp nylon carbon.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpsipp19zuf.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap2_zpswl6etlx2.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap3_zps7qqukmo2.png

**
**

or perhaps something like this affixed with quarter turns

https://oi1249.photobucket.com/albums/hh519/semelton500/cap4_zpsehon8xvk.png

Vlad

12-19-2019, 07:30 AM

Interested in cowl winter kit Steve. Also I don?t see the heater adapter on the website. I remember you developed one to preheat the engine from the bottom.

Steve Melton

12-19-2019, 09:45 AM

Preheater adapter is still going stong. I will add it, but it requires some assembly work by the user.

https://static.wixstatic.com/media/42b789_5e802c22cd8e4ef8818687051ff88004~mv2.png/v1/fill/w_440,h_318,al_c,q_90,usm_0.66_1.00_0.01/42b789_5e802c22cd8e4ef8818687051ff88004~mv2.webp

Steve Melton

12-23-2019, 04:37 PM

flight checking cowl air dam. still on Wichita fuel.

it's simple and effective. I need to expand it and plan for attachment. there is enough room even for a 9 to put a hand in the front and attach with quarter turn butterflys. when it's removed you will never see the attachment features because they will be hidden in the cowl.

https://static.wixstatic.com/media/42b789_2973ff1cf0c6463bbf3040f5660e6e8c~mv2.jpg/v1/fill/w_613,h_817/IMG_20191223_152853.jpg

https://static.wixstatic.com/media/42b789_0c37a2cccec64ee7b22a4200bc00c67d~mv2.jpg/v1/fill/w_650,h_866/IMG_20191223_153957.jpg

https://static.wixstatic.com/media/42b789_f31c402530564c75aa7f8bebdca28ade~mv2.jpg/v1/fill/w_1089,h_817/IMG_20191223_164043.jpg

Steve Melton

12-25-2019, 03:38 PM

warm today, 15C.

these are the itty bitty titties.

delta: CHT increase 40F. Oil temp increas 20F. Limited testing.

Second test flight from Cincy, still flying on Wichita fuel. One more flight planned using Wichita fuel and I will still have 1 hr in the tanks. Wichita to Cincy was 610 nm. Comprehend the fuel efficiency.

https://static.wixstatic.com/media/42b789_dd6c740aef794fcdae2d694befc8bfef~mv2.jpg/v1/fill/w_1175,h_881/IMG_20191225_143729.jpg

https://static.wixstatic.com/media/42b789_751e2f325ebd433ab6df3cdb9463ddb8~mv2.jpg/v1/fill/w_1110,h_832/IMG_20191225_131931.jpg

https://static.wixstatic.com/media/42b789_7ca61e309db744ec99bf6ea575e1e7f8~mv2.jpg/v1/fill/w_1110,h_832/IMG_20191225_145747.jpg

Steve Melton

12-25-2019, 08:09 PM

first time to print them in black. pretty cool. I thought I would get a photo before they leave tomorrow.

https://static.wixstatic.com/media/42b789_e48ae429f29e47d1b4edb3c04e6c37a6~mv2.jpg/v1/fill/w_800,h_600/DSCN2038.JPG.jpg

Steve Melton

12-28-2019, 07:04 AM

I really like this gust lock pouch. Abby at Flight Line Interiors made the prototype but didn't want to get into production even after requests from others. If someone knows where I could have some made, let me know. Or if someone wants to make them and put them on my website that would be good.

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190929_103058_zpscfmiu1l5.jpg

Steve Melton

12-30-2019, 05:16 PM

I can't get these close to failure with these straps. Thin web, black. Mounted against a hard alum edge, similar to the elevator. Standing in the line of fire. Need to switch from straps to chain. Load spiked to 350 lb and then ropes and straps relaxed over the next 30 minutes to 314 lb. 300 lb is a 3X safety factor for 87 kt wind for a trailing edge rudder gust lock.

https://live.staticflickr.com/65535/49301826116_0a2c0e6189_z.jpg

https://live.staticflickr.com/65535/49301348978_a17c04ba0b_c.jpg

https://live.staticflickr.com/65535/49302051002_8b4758129d_c.jpg

Steve Melton

12-31-2019, 07:16 AM

now also in Yellow

https://live.staticflickr.com/65535/49304226783_85c8a065eb_m.jpg

laz

12-31-2019, 04:00 PM

Steve If you give me dimensions I can make a few of the pouches.

Send me a Message.

Laz

Steve Melton

12-31-2019, 04:43 PM

thx, will send to you. the main thing is to be able to see all four gust lock pieces are stowed for safety.

I would prefer a zipper on the top and handle on the end instead of the top. that way you can hold the pouch by the handle with the left hand and install the gust locks from right to left and the line feeds from the pouch easily. I think with the mods the pouch will be easier to make.

Steve Melton

01-01-2020, 09:09 PM

Air Dams installed. 10 stabilization.

OAT 0C at 4K ft

CHT
1 348F
2 364F
3 358F
4 348F

oil 180F

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

Air Dams removed. 10 min stabilization.

OAT 1C at 4K ft

CHT
1 324
2 317
3 326
4 318

oil 170F

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

similar to previous flights, I see cylinders 2 and 3 CHT 10-15F hotter than the others with dams installed. I don't understand this yet. I think I would like to have 20F increase in CHT and oil temp and better CHT distribution.

oil cooler is taped over at the baffle inlet for both tests.

https://live.staticflickr.com/65535/49313884191_0e6173d79f_c.jpg

Bevan

01-01-2020, 11:29 PM

Looks good Steve.

Since there?s less air flowing through the cowl, there should be less cooling drag. Did you notice or have any thoughts on speed increase?

Bevan

Air Dams installed. 10 stabilization.

OAT 0C at 4K ft

CHT
1 348F
2 364F
3 358F
4 348F

oil 180F

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

Air Dams removed. 10 min stabilization.

OAT 1C at 4K ft

CHT
1 324
2 317
3 326
4 318

oil 170F

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

similar to previous flights, I see cylinders 2 and 3 CHT 10-15F hotter than the others with dams installed. I don't understand this yet. I think I would like to have 20F increase in CHT and oil temp and better CHT distribution.

oil cooler is taped over at the baffle inlet for both tests.

https://live.staticflickr.com/65535/49313884191_0e6173d79f_c.jpg

Steve Melton

01-02-2020, 09:42 AM

theoretically there must be some speed gain but I wasn't focused on that at the time. what I want to do is get the CHT distribution correct firstly. it may require bigger and more shapely boobs.

Snowflake

01-03-2020, 07:53 AM

theoretically there must be some speed gain but I wasn't focused on that at the time. what I want to do is get the CHT distribution correct firstly. it may require bigger and more shapely boobs.
What you're controlling is the amount of air coming into each side of the cowling, but you're not controlling where it goes once it's in.

If you want to change the front to back distribution of air flow (more air = more cooling), you'll need to affect the amount of air that goes to the front and rear cylinders. On mine, my front cylinders were running cooler and the rear ones hotter. I used foil tape to mask a line about 3/4" high across the front of the front cylinder on each side. That blocked air flow through that portion of the front cylinder, and forced more air back to the rear cylinder... resulting in more balanced temps.

If you have a hot front cylinder and a cool rear one, I don't think masking off the main inlet is going to help that front cylinder at all.

ALagonia

01-03-2020, 08:32 AM

On my 9 with an O-360 my #4 cylinder always ran hotter than all the others. I tried the foil tape on #?s 1 and 2 cylinders of different sizes. Ultimately I ended up with about 3/8? foil tape on the #1 cylinder and all my CHT?s are now very close. Most important the #4 cylinder CHT dropped significantly.
The other thing I did, as a result from a post I read here, is to slightly, very slightly, reduce throttle during the climb and have found that #4 CHT comes down immediately without reducing fuel flow. That was a great tip.

Steve Melton

01-04-2020, 12:19 PM

first one to print. very strong. I could not fail the edges by hand force. feather weight. could be custom dimensions.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2097_zps9zhmf189.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/cap3_zpsclznv7vk.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpsobhlcfrg.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap2_zpszhmamubo.png

Steve Melton

01-04-2020, 09:50 PM

looks like a cowbell. rope passes thru and extends from side to side for elevator gust locks. I may add a couple slots at the bottom. gust lock axial length = 1.15 inch.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpss3paevcx.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap2_zpsnjnwna7m.png

https://oi1249.photobucket.com/albums/hh519/semelton500/rudder_image_zpszaz2y6ry.jpg

*****
first one to print. a couple of areas to correct but mostly OK. need to increase the set back of the vertical contact tang.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2109_zpszkvjsgkr.jpg

*****

working some printing details and fit. with gust lock installed, rudder trailing edge movement is .25 inch.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2111_zpsy08web5p.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2110_zps8zpeto0n.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20200106_191601_zpsgp9gc8qm.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20200106_191509_zpsg6azkcng.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20200106_192528_zpsq98n31bb.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/cap3_zpspljkk4nc.png

Steve Melton

01-05-2020, 06:56 AM

beginning panel dock for 740b. this one will fit the slot and brackets for my AVMAP4. no panel mod required.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpsvrjrmozl.png

Steve Melton

01-05-2020, 04:54 PM

more uniform except for number 1. I still don't understand it. 15 minute stabilization.

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20200105_130552_zpsuc96zk8p.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20200105_130426_zpsgh7vibtg.jpg

Snowflake

01-06-2020, 08:01 AM

#1 needs less cooling air, #3 needs more. You need a dam that deflects air up over #1 to the back of the case, where it can flow through #3.

Try a 1" strip of foil tape across the front of the cylinder (horizontally) right down at the baffle. Cut the strip or add to it and see the variation in temps in flight.

Steve Melton

01-10-2020, 08:10 PM

the rope is almost straight across. I like that.

pull testing is pending printed tooling.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2157_zps83zc1mp6.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2174_zps5tknfseu.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2171_zpsywjhfgsa.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2170_zpsiskhb5js.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2159_zpsidzgzu93.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2145_zpsbvwezznx.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2142_zpssm5vrknq.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2135_zpsjz557f7g.jpg

**

pull test tooling. this one will be loaded in pure tension and will be good test. since this is pure tension I expect the result to be less than the elevator gust locks that are loaded primarily in shear. I plan to use some lanyards to catch it when it fails.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2178_zpsuqejfh1p.jpg

Steve Melton

01-12-2020, 06:30 PM

some load testing. strength was a little more than I had predicted.

I tested both a .05 inch and .075 inner fillet radius. both of these fit the rudder slot fine but I was interested in the effect. web thickness = .068 inch.

I haven't done the final calculation but I estimate 250 lb capability will allow for 2X safety factor for 87 knot wind. this does not include impact loading but that should be low since the rudder is movement is small with the gust lock installed.

if you try this test at home, be sure to lanyard everything because parts will fly. no humans or animals were injured during this testing. :)

test setup. tooling placed in same location as rudder contact.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2185_zpstcweu2jw.jpg

**

test summary

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2251_zpsnxoufjhh.jpg

**

test 2 sustained load of 250 lb, one can see the strain by the white discoloration at the fillet edges.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2234_zps8ayejdx2.jpg

**

failure specimens

test 1, 225 lb sustained load. when I applied more load it failed.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2214_zpsulv1stsn.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2199_zpscmnljudd.jpg

**

test 2, sustained load 250 lb. when I applied more load it failed.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2246_zpspv63n9dm.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2231_zpsol52d3qd.jpg

Steve Melton

01-14-2020, 07:29 PM

because I like to break stuff under control....

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2259_zpsvdl5hmhv.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2266_zpsbpd8m8vd.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2276_zpstgv5p99u.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2269_zps2plse1bb.jpg

****

new concept, undercut fillet to be tested. here I go, down a rabbet hole again...

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

Snowflake

01-15-2020, 08:09 AM

Prediction: The recessed fillet won't help you, unless you can increase the radius significantly. It looks like the outer layers are failing, which suggests to me that they are peeling from the inner layers at some point and you're not getting the full strength effect of the increased cross-section.

If you could start by tapering the thickness first, say 30 degree taper out to 1.5x the thickness, *then* radius it into the stops, you'd distribute the load better. Even better, use an elliptical fillet, that extends longer across the web, and shorter across the stop. That would remove the stress concentration you'd get at the start of a taper.

Steve Melton

01-15-2020, 10:30 AM

I have a couple versions to test. it's playtime.

Steve Melton

01-16-2020, 07:51 PM

some interesting results.

All tested articles have undercut fillet radius. I found the undercut fillet to have better seating in the rudder slot and since the fillets are recessed there was no interference edge contact. This will allow for a slightly thicker web in the same space.

Failure loads:
Test 1 = 200 lb
Test 2 = 320 lb
Test 3 = 200 lb
Test 4 = 340 lb
Test 5 = 230 lb

Conclusions are:
1. a larger fillet radius is beneficial
2. a thicker web is beneficial
3. a large chamfer (taper) on the edge of the lower region had adverse load effects. ( I didn't expect this )

Follow-on testing is to combine the features of Test 2 and Test 4 and retest. I may be able to sustain over 400 lb failure load with this combination.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2286_zpseobnf1ot.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2317_zps6dava45l.jpg

***

zero condition

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2287_zps71b8035e.jpg

***

Test 2

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2306_zps6vcrcgti.jpg

***

Test 4

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2315_zpsfcczdk2j.jpg

***

I am satisfied with the progress so far. Cool temps = good climb performance. Pulling to vertical. Cincinnati, Jan 16, 2020.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2280_zpsaghorfoz.jpg

Snowflake

01-16-2020, 09:59 PM

Failure loads:
Test 1 = 200 lb
Test 2 = 320 lb
Test 3 = 200 lb
Test 4 = 340 lb
Test 5 = 230 lb

Conclusions are:
3. a large chamfer (taper) on the edge of the lower region had adverse load effects. ( I didn't expect this )

Your results and photos makes me question conclusion #3. If i'm reading the pictures correctly, Tests 1 and 4 had small chamfer, and Tests 3 and 5 had large chamfer.
- Test 1 and Test 3 had the same failure load
- Test 4 and Test 5 showed a reduction in load carrying

So one test that shows no effect, and one that only shows correlation?

Steve Melton

01-17-2020, 07:39 PM

Test 1 = 405 lb (max was 430 lb before rope stretch settling)
Test 2 = 385 lb

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2322_zpswoaqgtcl.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2330_zpsqnwv6qho.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2323_zpsxie6c5zl.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2328_zpsdzivlveq.jpg

*********

that's enough of that setup. it was scary.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2335_zpsuanzdtco.jpg

cderk

01-18-2020, 02:49 PM

I?m really confused... in order to install this, it seems like you?d need a ladder? Am I missing something?

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2174_zps5tknfseu.jpg

RV8JD

01-18-2020, 02:56 PM

I’m really confused... in order to install this, it seems like you’d need a ladder? Am I missing something?

These are the ones for tailwheel equipped RVs. See the title of Post #1186. Steve is just using his -9A for fitting.

cderk

01-19-2020, 04:31 AM

These are the ones for tailwheel equipped RVs. See the title of Post #1186. Steve is just using his -9A for fitting.

Got it - makes WAY more sense. Lol

RV Wannabe

01-19-2020, 09:05 AM

Hi Steve,
Sent you a PM about printing.
Thanks
Mark

Steve Melton

01-20-2020, 07:59 PM

some gap spacers needed for tight fitment.

aft side on mine, .058 inch each side. 116 total
fwd side on mine, .012 inch one side, .012 total

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20200120_144845_zpsohdljffi.jpg

aft side

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20200120_151500_zpsglu95k87.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20200120_150456_zpsqdhtr9z7.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20200120_151644_zpsrs03styh.jpg

***

fwd side

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20200120_151521_zpsxuyy4jey.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20200120_151741_zpsv5qg68bu.jpg

***

yellow had a lower pull test value of 335 lb. vs red 385 lb.

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20200120_144750_zpsiuijyy7t.jpg

Steve Melton

01-21-2020, 06:24 PM

blockage placed in the middle resulted in CHT within 10F distribution of all. CHT and oil temp rise was approx 10F. it's better in the middle than at the edges. imagine that.

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20200121_181716_zpsbj1czbg3.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20200121_181729_zps4y7vjix7.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20200121_181708_zps8un57kuh.jpg

Steve Melton

01-22-2020, 04:03 AM

what about a very simple single piece? adds blockage but may be better for cooling when in extended climb. it should have less vortex shedding vibration than a flat plate.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpsiittblrr.png

Snowflake

01-22-2020, 07:59 AM

what about a very simple single piece? adds blockage but may be better for cooling when in extended climb. it should have less vortex shedding vibration than a flat plate.
The vortex shedding may be contributing to better airflow distribution though, kind of "randomizing" the airflow through the cylinder.

Steve Melton

01-22-2020, 05:45 PM

warm today, 4C, some numbers. difficult to access when it is in the middle but that's the best location.

oil cooler is taped over at the inlet on the upper baffle side.

the width on this one = 1.5 inch

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20200122_183536_zpsi4htppp3.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20200122_182427_zpseaxcc7wx.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20200122_171700_zpsovanxsnk.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20200122_181804_zpsnz46jsja.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20200122_181747_zpszkgrkfx7.jpg

Steve Melton

01-22-2020, 05:55 PM

offset pad added to reduce the teflon build-up required to make tight.

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20200122_165543_zpsr5zsnmto.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20200122_165336_zps1y6qaagi.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20200122_165418_zps94c7uh5d.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20200122_165613_zpsprtlvnid.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/cap4_zps4gorot2e.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap5_zpskicwkcum.png

Steve Melton

01-23-2020, 04:43 AM

New boxes and small envelopes - First Class Mail - it's a couple days longer but if we can save several dollars we will ship this way and refund the shipping difference.

First class box = $5.12
Small Envelope = $2.76

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2339_zpsnoueemc9.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2340_zps08hfrlhr.jpg

Steve Melton

01-23-2020, 04:03 PM

A general purpose gust lock using .032 alum and a couple pins or bolts. The user supplies the .032 alum.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpsw2y5h0i8.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap2_zpsdqheowji.png

scsmith

01-23-2020, 04:25 PM

pull test tooling. this one will be loaded in pure tension and will be good test. since this is pure tension I expect the result to be less than the elevator gust locks that are loaded primarily in shear. I plan to use some lanyards to catch it when it fails.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2178_zpsuqejfh1p.jpg

Steve:

I wonder if you could make a more representative test fixture by just relieving one jaw on each pull fixture, and turn them so the engaged jaws are on opposite sides. The lack of contact on the relieved sides will make the fixture rotate some, and probably get contact on the web of the gust lock, as well on pulling on the flanges on opposite sides. That web contact may cause some additional bending of the web, but not in the same place as the local bending at the filet from the one-sided loading that is mostly shear, but also "short-beam bending".

The strength trends related to filet size may be quite different when loaded this way rather than the straight tension loading.

scsmith

01-23-2020, 04:28 PM

Steve Melton

01-23-2020, 04:47 PM

Agreed, it's not a perfect test. It will never be a perfect test unless it is mounted on an aircraft and strained to failure. I just need an aircraft to test it to failure, but not mine. I don't plan to do any more testing of this piece. My test setup was somewhat dangerous and I'm staying away from it. It is what it is, the best I could do at this moment.

I thought the 7 and 9 had the same vertical stab and rudder but maybe they are different. I believe the 8 is slightly different.

Steve Melton

01-24-2020, 05:51 AM

investigating a couple of options for general purpose gust locks with .032 alum web

https://oi1249.photobucket.com/albums/hh519/semelton500/cap3_zpslg2wcuyr.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap4_zpsq6ueeny8.png

Steve Melton

01-25-2020, 06:54 PM

more rib forming tools for something new. beefy parts.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpsrybzsvmc.png

***

automotive part

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpsqinnn6ts.png

scsmith

01-25-2020, 07:09 PM

I thought the 7 and 9 had the same vertical stab and rudder but maybe they are different. I believe the 8 is slightly different.

The key thing that is different is the height of the fiberglass tip cap that is used for each. The 7 and 8 originally had a shorter one, and the 9 had a much taller one. Then they started using the one from the 9 on the 7.

It is critical in your product because you want the plastic part to extend down far enough so the end bares on the aluminum below the fiberglass fairing.

Steve Melton

01-25-2020, 07:14 PM

appreciate that information

sahrens

01-26-2020, 08:30 AM

more rib forming tools for something new. beefy parts.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpsrybzsvmc.png

It is for forming flap nose ribs on a Bearhawk Patrol, my RV-15

Steve Melton

01-26-2020, 07:49 PM

I printed this dehydrator cap from Thingiverse or somewhere. it was too big and didn't fit. I need to design my own.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2372_zpsmss6zgsq.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2373_zpsytcqz7fw.jpg

***

first time to print the fuel sump mount in red. I really like it. No trouble locating it since it's red. I have one mounted on the wall in my hangar and I cycle it at least 10 times each time I visit. it must have a thousand cycles by now and it's in perfect condition. it's very light weight.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2344_zpsrxfv8ss0.jpg

***

General purpose gust lock with .032 alum web. I over killed it with the 3/8" dia pin. it doesn't need that. I will reduce to 1/4" inch pin size but overall I think it has promise.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2355_zpsoxt0reja.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2346_zpsbtbumlnh.jpg

Steve Melton

01-26-2020, 08:00 PM

and feeling good about them except I need to find an easy method to attach them. oil cooler is taped over.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2367_zpswrry0rrz.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2369_zpsvwfwi2k2.jpg

three cloud layers... that I could see, maybe there are more. very beautiful.

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20200126_160114_zpstw8anfo2.jpg

Steve Melton

01-27-2020, 04:47 PM

Both of these should have similar strength. Mix and match as slot size is the same for both.

High profile - easy to access pins

https://oi1249.photobucket.com/albums/hh519/semelton500/cap5A_zps8hbcposb.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap5B_zpsbbfxbnnb.png

**

Low profile - compact design

https://oi1249.photobucket.com/albums/hh519/semelton500/cap6A_zpsnqmwhgo2.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap6B_zpsdlqkvm5n.png

CT Brietigam

01-27-2020, 09:01 PM

Hello Steve, as an unintended consequence for installing my Skyview SV-COM-X25 radios low in the panel (not in direct line of sight), they are very difficult to read. It's very problematic and challenging switching frequencies and accessing information. Would it be possible to made a small bezel for the radios that would rotate the face about thirty degrees upward? I think a small bracket/bezel would do the trick. Thank you, Chuck Brietigam
RV-6XXL

Steve Melton

01-27-2020, 09:09 PM

CT Brietigam

01-28-2020, 07:27 AM

Good morning Steve,
I tried to post a copy of the Dynon Skyview radio installation cutout diagram, but failed. It is readily available on Dynon's website under Skyview system. The radios are offered in both horizontal and vertical mounts. Mine are both horizontally mounted. Thanks a bunch for your interest. Chuck

PS: i sent it to your via your email address.

Steve Melton

01-28-2020, 07:06 PM

first time to print in Red. these are going to Italy. I try to put a some artwork elegance in each piece. sometimes I succeed.

Another one today in black is headed to Alaska.

I like the fact that these get around.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2401_zpsmloved89.jpg

Steve Melton

01-29-2020, 03:57 PM

do not try to tighten these, they are only a reflection.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2478_zpsu2y75vvy.jpg

*********

enough of my paint, now to the important stuff, gust locks.

low profile, metal web

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2410_zpsbldnbohx.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2411_zpsi9mk46kh.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2417_zpshrdfrwc3.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2420_zpsl3vllcog.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2422_zpsd5t9tvks.jpg

********

high profile

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2434_zpshsidth9x.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2435_zpsc63jse0c.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2437_zps8mrl6qcx.jpg

Steve Melton

01-29-2020, 03:58 PM

high profile and low profile compare

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2442_zpsjhipqqxp.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2443_zpsibdvuus6.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2444_zpsgjln8qrq.jpg

**

low profile range of motion = 12 degree total. ensures the gust locks are flat against the surfaces.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2427_zpsxbovpl5w.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2428_zpsqldczm2s.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2405_zpsgfzqqd30.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2402_zps62tch1cl.jpg

Steve Melton

01-30-2020, 09:38 AM

single web

high profile

https://oi1249.photobucket.com/albums/hh519/semelton500/cap11_zpsh6bctj7j.png

***

low profile

https://oi1249.photobucket.com/albums/hh519/semelton500/cap10_zpslhzcpzjl.png

Steve Melton

01-30-2020, 07:39 PM

with pin. that's about at easy as it gets. printed as a solid piece. UV resistant plastic. will not scratch paint. the user supplies the .032 alum strip. slot is 1 inch long. pin = 1/4 inch dia.

these are general purpose gust locks, put them where you want, but better to place them as far as possible from the hinge line and let physics work for you.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2488_zps7o9ivxbf.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2490_zpsqg7bmdgm.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2487_zpsc3rsb1pa.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2479_zpsqwx7f6jo.jpg

Steve Melton

01-31-2020, 09:35 PM

similar to the plastic version that can mount to a rudder gust lock with a rope but with a thin metal web. who knows, give it a try.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap7_zpsdvk3lw8o.png

Scott Hersha

02-01-2020, 07:37 PM

I like this one Steve. Especially the push-pin installation. This one should work with practically every RV airplane.

Still working on an RV4 non counterbalance rudder lock.

Steve Melton

02-01-2020, 09:14 PM

I like this one Steve. Especially the push-pin installation. This one should work with practically every RV airplane.

Still working on an RV4 non counterbalance rudder lock.

This is a the beginning of concept for a non-counterbalance rudder lock for a taildragger. Working with Bruce on this one and I'll show you when it's done.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpsdxnozgba.png

Steve Melton

02-01-2020, 09:18 PM

this one uses a .032 metal web. either bolts or push pins. has a hole for a rope connection to the rudder. web slot = 2.5 inches long.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2511_zpsbhmafgca.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2512_zpsm9q82fiz.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2513_zpsghwsuaxd.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2514_zpsektjzgae.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2516_zpsvtfy1uoq.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2519_zpsdogreufr.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2521_zpsxgksulto.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2524_zpswki8ty0u.jpg

******

******

side by side comparison. metal web = .032 inch. plastic web = .068 inch web. (this one is for an RV-7) plastic web version is printed to custom size measurements.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2539_zpsgtxnfyi3.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2542_zps6zqkidxt.jpg

Steve Melton

02-02-2020, 08:52 AM

if you ever see semi tubular rivets on an aircraft structure, walk away. we see them on brake lining replacement when we do them on RV's.

for plastics they are useful since they do not expand to the hole and crack the plastic but rather they only clamp and apply a tension force. they are not as strong as aircraft structural rivets.

this is retrofit plastic tips for a vintage car convertible top. see the semi tubular rivets.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2536_zpsqte5cp55.jpg

Steve Melton

02-02-2020, 08:38 PM

I bumped into this on the internet. it's copyrighted, but hey, I didn't give my permission for the photo either. my wife was with me for this trip to OSH. first time for her to camp with the airplane. we flew the high speed approach. as we were approaching Ripon they told everyone circling the lakes they were full up and to go somewhere else, but then said "Homebuilts come on in"! I think our ground speed from Ripon was 180 kts as there was no one else around. my wife asked is it always that easy. I said "sure is".

look at those flap fairings. go baby, go! Van did a really nice job on the 9.

I have to admit it, sometimes I just sit and look at my airplane and think, Wow!

https://oi1249.photobucket.com/albums/hh519/semelton500/001523284_zps1iklfuzd.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/flap_fairings_zps16rgx4st.png

scsmith

02-02-2020, 09:04 PM

thanks for the effort on the dipstick tube dehydrator cap. Sorry the geometry file wasn't right. In the thread where I found that, one reviewer did mention that the threads were too big, but anogher reviewer said it worked fine. So ??? Can you use that geometry as a starting point and modify it? Or does this basically mean starting over?

I printed this dehydrator cap from Thingiverse or somewhere. it was too big and didn't fit. I need to design my own.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2372_zpsmss6zgsq.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2373_zpsytcqz7fw.jpg

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first time to print the fuel sump mount in red. I really like it. No trouble locating it since it's red. I have one mounted on the wall in my hangar and I cycle it at least 10 times each time I visit. it must have a thousand cycles by now and it's in perfect condition. it's very light weight.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2344_zpsrxfv8ss0.jpg

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General purpose gust lock with .032 alum web. I over killed it with the 3/8" dia pin. it doesn't need that. I will reduce to 1/4" inch pin size but overall I think it has promise.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2355_zpsoxt0reja.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2346_zpsbtbumlnh.jpg

Steve Melton

02-02-2020, 09:14 PM

needs a dedicated design. it's on the board. Lycoming size = 1 1/4 inch diameter thread, Superior = 1 1/2 inch diameter. I will put a 3/8 inch dia female pipe thread in the middle. Give me a week.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpslkpr8xwi.png

Steve Melton

02-03-2020, 08:14 PM

threads turn well. I still plan to chase the 1 1/4" threads with a die when it arrives but it doesn't need it. the 3/8 NPT ID threads were cut. it has a bigger grip. I like it. ASA plastic has good resistance to oil and fuel.

I will bump up the size to 1 1/2" threads to fit Superior engines. I may even use it if I ever have some engine down time.

I have no idea why the lightweight version of this on Thingiverse or whatever didn't work as I printed it exactly. It was simply too large and not sized properly.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2565_zpsxsmabb95.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2564_zpsglnwfjhm.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2561_zpsfwt4u69w.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2560_zpsi13cusri.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2558_zpstefrupsy.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2555_zpspt90r5sr.jpg

Steve Melton

02-04-2020, 08:36 PM

after 3 years my left hand side fuel drain fairing has a crack. it was detected by by being able to rotate it in place slightly. it was not in danger of departing yet. I had tested these 3 years ago by placing them in fuel for weeks and they had no degradation but after some recent research I discovered that when exposed to alcohol (and presumably fuel) they become embrittled.

my left hand side fuel sump has had a fuel weep problem over the years and I think I finally have it cleared but the weeping did the damage to the fairing. I am still using the same fuel sump o-rings for the past 6 years.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2570_zpsvhsxlhuu.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2575_zpscehk9qss.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2574_zpsfoyr8rut.jpg

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the right hand side fuel sump has not had a weeping problem and the fairing is in good condition.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2390_zpsob8va5te.jpg

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***

I replaced the left hand side fairing with another made from ASA material that is reported to have 10X resistance to alcohol (and presumably fuel) embrittlement over ABS.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2386_zpsc8oexr5n.jpg

Steve Melton

02-04-2020, 08:49 PM

since printing plastic is new to aircraft usage I try to post a year end summary of the parts and show how they a doing. these are all original installs on my aircraft from anywhere from 3 yrs ago to present as I have added them. they are current photos as of late 2019 and Jan 2020.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2395_zpsjpddw6bo.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2377_zps8kr0vuf2.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190523_144858_zpsvtwdgcdx.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2379_zpsiecztqqg.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2382_zpshipbmvef.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2384_zpsfkd2doej.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2390_zpsadldqmcf.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190927_173638_zpspehavtdc.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190927_173645_zpsevkoapwd.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190528_184942_zps04hcuffh.jpg

Steve Melton

02-04-2020, 08:51 PM

continued

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20190216_150701_zpsfiuqw6ie.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/flap%20bracket%20fairings_zpshjbdy24u.png

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20191223_143040_zpsecmdaadf.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/IMG_20191013_160134_zpsxkd4hoyo.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2376_zpsstow5bc3.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2378_zpsle8e8akz.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/bug%20blades_zpspxll52i4.jpg

Snowflake

02-05-2020, 08:09 AM

Steve Melton

02-05-2020, 10:09 AM

Wow! All that plastic on one airplane! Almost need to re-do the W&B when it's all packed in for a flight. :)

It would be neat if all of the "removable" stuff (control guards, fuel cap cover) could fit inside, say, the stick cover so it would all "pack" for travel.

fuel cap cover is packed on the wall. it's magnetic and you can probably only do this if the magnetometer is all the way in the tail. otherwise you may have some interference. that's a good reason to put the magnetometer all the way in the back in case someone has a magnet in their baggage.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2380_zpsgxtpabhg.jpg

Steve Melton

02-06-2020, 06:24 AM

flap fairing extended in flight from 2018 Oshkosh

is it legal to post a copyrighted photo? this one just says "image by"

https://oi1249.photobucket.com/albums/hh519/semelton500/45211190114_a3fa2a4667_b_zps05iffajo.jpg

Snowflake

02-06-2020, 07:59 AM

is it legal to post a copyrighted photo? this one just says "image by"
Copyright automatically applies to the creator regardless of whether it's claimed. However, as long as you're only linking to the content on another site, and not creating a copy of your own, posting it somewhere else, and linking to it, you're golden. There's a clause somewhere in the laws that says simply linking to content isn't deemed to be a violation of copyright, but I don't know the exact chapter and verse...

Steve Melton

02-06-2020, 05:25 PM

in process work. directions are "to be absolute min mounting dimensions".

30 degree angle.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpstvuzfkrp.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap2_zps60mzmshd.png

Steve Melton

02-07-2020, 03:13 PM

I'm happy with this first print. fit's like a glove, slides in easily. I'll open it up .010 inch for some mfg. margin and tweak a print setting. I will add some custom ordered #6 inserts (due to arrive Monday) and it's done. I'm pleased with how this turned out and would be proud to have it in my aircraft.

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2585_zpsmpyl5zfb.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2582_zpstgiwxarl.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2580_zps1erocxp2.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2586_zpskpu1l0nf.jpg

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***

it's a compact design

https://oi1249.photobucket.com/albums/hh519/semelton500/cap3_zpscmirpaes.png

CT Brietigam

02-08-2020, 08:25 AM

Steve,
Very, very nice work! That will make a huge improvement in my panel and the readability of the LCD face plate. Thank you very much!!!
Chuck Brietigam
RV-6XXL

Steve Melton

02-08-2020, 05:17 PM

1 1/4" dia = Lycoming
1 1/4" dia = Superior

Center thru hole = 3/8" pipe thread

perfectly smooth running threads

material = ASA plastic that is oil resistant

includes gasket

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2614_zpswwm4pomp.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2607_zpsdtbqd0m1.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2601_zpsb1lds2ru.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2594_zpsn5zxbxx7.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2587_zps5rmpchvh.jpg

https://oi1249.photobucket.com/albums/hh519/semelton500/DSCN2620_zps4umrb8i8.jpg

Steve Melton

02-09-2020, 08:18 AM

kicking around a concept to conceal another GPS antenna type under a RAMI shell.

https://oi1249.photobucket.com/albums/hh519/semelton500/cap1_zpsavy7u9cn.png

https://oi1249.photobucket.com/albums/hh519/semelton500/cap2_zpsprx5jtqk.png

flysrv10

02-09-2020, 10:33 AM

A recess along the bottom would help seal the underside with pro seal or RTV.

lr172

02-09-2020, 11:21 AM

Copyright automatically applies to the creator regardless of whether it's claimed.

In the US, copyright claims must be established and maintained. They are not automatic. Further, If the holder does not take active steps to identify/label and protect/defend the copyright claim, including taking action against all known violators, most infringement suits will be lost. Loosely similar to "squatter's rights." (other can claim rights to your property eventhough you hold clear title if you didn't take steps to prevent their use of that property - this is why you see no trespassing signs on vacant land) This is why you see copyright and trademarks labels on everything you touch. If it weren't necessary, they wouldn't bother. It is an issue of case law/precedence and not one of the law per se.

ownership of a "picture" is automatic. However, that provides no protection from other copying it or using it. Use is not restricted due to a digital picture being an intangible product/property. intangible products require licensing or copyrights for protection.

Larry