Edge 540 27.4% Build
10-04-2013, 07:17 AM
#52
Join Date: Jun 2003
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I followed you on the build of the Ryan and read your thread on the SW after you finished. I’m glad to catch this build just as you’re starting. I’ve only built one model from plans and that was back in the 1900’s 
. Didn’t have a scroll saw, sander or dermal just a cooping saw, exacto set and sandpaper. It was my third model and it came out pretty good for a rookie. I’m sure I’ll enjoy watching this build as much or more as the others.
. Didn’t have a scroll saw, sander or dermal just a cooping saw, exacto set and sandpaper. It was my third model and it came out pretty good for a rookie. I’m sure I’ll enjoy watching this build as much or more as the others.
10-04-2013, 07:25 PM
#54
Leroy
10-05-2013, 10:40 AM
#55
Thread Starter
Welcome back Maekju!
Thank you Leroy, those kind words have inspired me to start building, as I just received the wing tube, sleeve and wing bolts in the mail today. I have been so bored these past few days without any building to do.
Those of us that build are indeed fortunate to have such a wonderful hobby to pass the time...flying is just the icing on the cake!
So for you guys that have a few grey hairs (like me) and can remember the Jackie Gleason show: "And Away We Go...."
Thank you Leroy, those kind words have inspired me to start building, as I just received the wing tube, sleeve and wing bolts in the mail today. I have been so bored these past few days without any building to do.
Those of us that build are indeed fortunate to have such a wonderful hobby to pass the time...flying is just the icing on the cake! So for you guys that have a few grey hairs (like me) and can remember the Jackie Gleason show: "And Away We Go...."
Last edited by VincentJ; 10-05-2013 at 01:07 PM.
10-06-2013, 06:47 AM
#57
Thread Starter
Yes I did buy them from Aztech Gary (as you suggested) and yes on the color!
As I stated from the start of this project I was going to incorporate carbon fiber into this build to help strengthen the structure. The wing spars are one of the first areas to receive the CF. Dimensions of the CF for the spars are 3/8" x 24" with a thickness of .007". I epoxied each piece on one side of each spar only, the CF will be orientated facing outwards. A word of caution when using CF, although it will add a tremendous amount of strength without much of a weight penalty, care must be used anytime working with this product. Sanding the CF can and will cause permanent lung damage, so be sure to use a respirator and care must also be exercised in preventing slivers from getting into your skin when handling it.
After the epoxy had cured, the spar was pinned to the plans. Since the CF doesn't go the full length of the spar I used some 1/32" ply for shims on the wing tip side to keep everything properly aligned. Next I removed the aileron portion of each rib with a gentle snap which was then followed by some gentle sanding to true up the ends. You can now see why I numbered the ribs and the parts of the aileron riblets to ensure that they will later go on in the proper sequence. Each rib's spar notch depth had to be adjusted for the additional .007" thickness of the CF, this was easily accomplished with a sharp blade on my hobby knife.
I have learned very early in this build that dealing with wing ribs that have a thickness of 1/16", that you have to treat them very gently and keeping them straight and in the position that you want takes a bit more effort...
As I stated from the start of this project I was going to incorporate carbon fiber into this build to help strengthen the structure. The wing spars are one of the first areas to receive the CF. Dimensions of the CF for the spars are 3/8" x 24" with a thickness of .007". I epoxied each piece on one side of each spar only, the CF will be orientated facing outwards. A word of caution when using CF, although it will add a tremendous amount of strength without much of a weight penalty, care must be used anytime working with this product. Sanding the CF can and will cause permanent lung damage, so be sure to use a respirator and care must also be exercised in preventing slivers from getting into your skin when handling it.
After the epoxy had cured, the spar was pinned to the plans. Since the CF doesn't go the full length of the spar I used some 1/32" ply for shims on the wing tip side to keep everything properly aligned. Next I removed the aileron portion of each rib with a gentle snap which was then followed by some gentle sanding to true up the ends. You can now see why I numbered the ribs and the parts of the aileron riblets to ensure that they will later go on in the proper sequence. Each rib's spar notch depth had to be adjusted for the additional .007" thickness of the CF, this was easily accomplished with a sharp blade on my hobby knife.
I have learned very early in this build that dealing with wing ribs that have a thickness of 1/16", that you have to treat them very gently and keeping them straight and in the position that you want takes a bit more effort...
Last edited by VincentJ; 10-06-2013 at 10:55 AM.
10-06-2013, 10:36 AM
#61
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Well, there certainly are many full scale schemes out there if one decided to emulate any of them. http://jetphotos.net/showphotos.php?...o%20Edge%20540
10-06-2013, 01:32 PM
#62
Thread Starter
Thanks Robert, it's nice to have something to work on again!
Ribs are now in place. Plans call for the ribs to be installed at a one degree tilt (towards wing tip), so I made some wooden jigs to help with proper placement. Wing tube has also been installed although not yet glued as well as the servo lead tube. This tube is actually a 1/2" rocket tube that I bought. The tube wasn't long enough to make a complete run so instead of gluing the tubes together I chose to use a 1" length of 1/2" heat shrink tube to splice the tubes together. It worked great.
Ribs are now in place. Plans call for the ribs to be installed at a one degree tilt (towards wing tip), so I made some wooden jigs to help with proper placement. Wing tube has also been installed although not yet glued as well as the servo lead tube. This tube is actually a 1/2" rocket tube that I bought. The tube wasn't long enough to make a complete run so instead of gluing the tubes together I chose to use a 1" length of 1/2" heat shrink tube to splice the tubes together. It worked great.
10-06-2013, 01:53 PM
#65
Thread Starter
Last edited by VincentJ; 10-06-2013 at 03:07 PM.
10-06-2013, 02:56 PM
#67
Thread Starter
Not a silly question Kevin. The blue tape is to help support the bottom tabs of the ribs which tend to snap off before their useful intent is done with. They will be removed before I snap the tabs off to sheet the wing. The laser cutting is extremely accurate, a far cry from die crushing I mean cutting...LOL
Last edited by VincentJ; 10-06-2013 at 02:59 PM.
10-07-2013, 01:31 AM
#69
Join Date: Jun 2012
Location: Bristol, CT
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Hey VJ, looking good so far. Nice to get going, huh? I just realized last night how much I use that blue painters tape to build, ( as I was buying another two pack.) especially since I stopped using CA and switched almost completely to titebond. I certainly don't miss it at all. Steve.
10-07-2013, 02:44 AM
#70
Thread Starter
Bob, my goal will be to have it come in somewhere between 15-16 pounds. Everyone that has this type of plane usually opts for plastic covering to keep it as light as possible, I intend to glass the wings and possibly the fuse as well...plans may change.
10-07-2013, 04:45 AM
#71
I will also be following along throughout your build.
Bob
10-07-2013, 05:03 AM
#74
Thread Starter
That makes two of us...LOL
This will be a good experiment as most weight when glassing is from the overuse of resin. I will be a miser when I apply the resin, just enough to get good contact between cloth and sheeting...
Maekju, the plans have hand written annotations by Doug Lee on them as well as some build notes with photos that accompany the plans.
Last edited by VincentJ; 10-07-2013 at 05:11 AM.