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Mark,
I would love to help with this or any of your other ideas to incorporate 3D printing. If you have the resources to create the CAD design within your business, we could help with the printing of the prototypes and final part. Shoot, even if you don't, we can help with the design here. We have the new HP Multi Jet Fusion 3D printer and we are able to print parts in production nylon pa12. This material and process will without a doubt be strong enough to handle the job. Also with this material, unlike other 3D print materials, will withstand time in the sun without any deterioration in properties. This is a durable and high temperature resistant nylon, just as when used in injection molding. I will post a link more info on the machine and process. Give me a call to discuss when you get the chance. 614-834-8659 http://aerosportmodeling.com/hp-jet-fusion-3d-printing/ |
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This is experimental aviation, right? Well, here's an experiment:
Yes, those are copper 45 degree elbows acquired in the plumbing aisle. Since those elbows are 1-1/8" ID and our sticks are 1" OD, I have used sections of scrap 6061 aluminum tube as bushings. It's actually from my first attempt at making the long elevator pushrod. That tube is conveniently 1" ID and 1-1/8" OD. Perfect for what I wanted. All riveted together with LP4 pop rivets (as also used on the elevator push rod). Needless to say, it's pretty "industrial" looking and I will dress it up and re-attach my Infinity grip. I'm sure it's not what you'd want in an Extra 300, but I think it will be more than adequate for what we do in an RV. OK, you may go ahead and start laughing! :D |
How are you going to test that thing?
What limit loads and what load cases will you use to test it - and what test factors of safety? Dave |
I have no plan at this time to conduct scientific load testing nor do I think it's necessary for the plane I fly or the way I fly.
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Brave man. Very brave.
If you mount the stick on its side so it's horizontal and put your full weight on the new end, that would be a reasonable test. Then rotate 90 degrees and repeat. Dave |
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I suspect that you have the force levels/locations reversed. The farther out on the lever, the lower the force, and longer the throw required.
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In re the stick, I will be cautious and in the very unlikely case that my crappy shade tree engineering fails, I'll slide my hand down 6 inches to what's left of the official, highly engineered and tested piece of 4130 steel tubing provided by Vans, and then land the plane! |
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