Kyle Communications

Well the Mistress left wing now has some company..The right wing is done and in the rack. I have my hangar space with only parts sitting in there. 4 wings and one set of tailfeathers for a savannah. Soon the savannah bits will be joined by the fuselage.

06/10/23 Installed RH wing fuel tank retention brackets. Bolted and riveted root rib to front and rear spars. Riveted upper and lower wing skins to root ribs and fuel tank supports. Second (RH) wing complete. 2.9h

The Bambu Labs unit really prints the layers super accurately and they seem to bond exceptionally well. These ones are just PLA but I may print a set in ABS as the Bambu has a heated chamber and apparently does very well. I tested to breakage one the the PLA first ones at 15% infill and it was pretty good. At 60% infill its really strong..there isnt any stress on it where it is. The rivets will pull through the covers if the chute is deployed

Marty I have had several bed slingers and fixed or modified a few of my mates ones as well. Always some sort of dicking around with settings or whatever and changing filament can be a real PIA at times. Also the quality of the printing can be a little "rough" at times too depending on how well you tune your slicer software. My BIQU crapped itself a few months ago but I do have a RatRig Vcore3 here that I got about 12 months ago but havent had the time to put it together but I had been keeping an eye on what was out there. Core XY is really the way to go for a 3D printer as you dont have the momentum of the bed to worry about. Thats why I got the RatRig and with the accelerometer you can get rid of most of the ringing on your prints. Bambu Labs came out with a rush with the X1 Carbon but its the top end one but really the extra 800 bucks really isnt worth it. The screen is nice sure but the Lidar they use seems a bit hit and miss. I went with the middle one with the 4 rack AMS cost about $1600 bucks..hedged at the price but was seeing too many good things about it. It arrived a week after ordering...holy crap the easiest thing to get going ..the speed is unbeliveable and the quality is beyond anything I have ever seen in real life come off a 3D printer. The engineers that founded Bambu are all ex DJI drone guys so you know the electronics and software is pretty slick..and it is. The automatic material system is just so good.No feeding filament anymore it does the intial loading automatically and changing when you select which one you want to print. I use the Bambu App on the computer and its connected to wifi and it just all works not to mention I can start a print and then go out the I can be anywhere and oen the app on my phone and look at the camera thats in there to make sure its all printing ok. To date touch wood I have not had one failure print. Everyone is just fantastic so much better than I am used to. Some examples I printed below

Time flies the older you get..I cant belive its been that long myself. It went along pretty well for a year or two then life pretty much got in the way and the speed of the project dropped off dramatically. Looking after 2 oldies here and building houses 300km away from here etc etc..but now I am retired.......hahahah I still have lots of things I am trying to get done but at least I have 3 more 24hr days to use.....By the way our house at the farm we started 3 years ago has finally got council approval last friday...so thats a big load off.

Check my blog. just fitting a after market parachute to my Savannah S

Hey its been a while since I have been able to get back to work on Mabel. I really have to finsih some stuff on her so I can get her down to the hamgar. I need the build shed for storage for a big redevelopment project here at Burpengary then the build shed will also be pulled down and the new shed to be put up will be the new build shed. The straps for the parachute are different to what are supplied by ICP and their parachutes so had to make some mods. The rear straps go around the undercarriage then come up the back but this version they come out of the upper fuselage skin using the rear overhead bar as the backstop if deployed. The kevlar straps are then exposed to the outside so I wanted to have them covered. I got on my Fusion 360 and designed up a cover then 3D printed a couple of versions and settled on this one that fits really nicely and should work well. I have a new Bambu Labs P1Ps printer..what a cracker..just a incredibly accurate and super fast printer. Once finished I can get the polycarb roof down to get film applied. I just need to fit the tray for the straps in the roof area and also sort out a cover for the main strap from the parachute that goes from the alu cover and under the polycarb in the middle at the back then onto the tray.

04/10/23 Drilled pilot holes for fuel tank retainer bracket in lower wing skin. Trial fitted fuel tank and root rib, mark filler cap opening. Cut filler cap and sight gauge holes, vacuumed and flushed swarf from fuel tank. Drilled and countersunk fuel cap flange holes. Fabricated fuel flange retainer. Installed fuel tank take-off fittings, reinstalled fuel tank with internal fuel tank support and installed filler flange and cap. 5.1h

Yes the LE is a extruded section basically a LE spar and so is the trailing edge or rear spar and the lot is held together with a truss in the centre

25/09/23 Matched drilled skin to rear spar. Removed all clecoes, deburred skin and spar, vacuumed wing cavity to remove swarf. Clecoed skin back in position, re-squared and levelled wing and completed riveting bottom RH wing skin. 4.4h

23/09/23 Riveted RH wing bottom wing skin to forward spar, stringer and ribs from leading edge to 5 rows forward of rear spar. 3.6h

My parachute came on a Emirates flight from Europe

My parachute is a GRS The dangerous goods thing is pretty over the top. The rockets are anchored and you have to remove that anchor when it is installed. I imported mine directly from the factory but I piggybacked the freight with the BRS agent here. I also found out a few things about how this dangerous goods" thing is done and who does it. I found out by accident and now know who to approach directly for the dangerous good import details . These devices all come to Qld because it is who does the dangerous good import and paperwork and internal freight here in OZ. I have to get another parachute for my RANS S-21 but its a bigger one than the 600kg and is a lot more expensive but I will be chasing the freight for it directly with my now updated knowledge of how to do it. The 6 years repack and rocket changeout I was not going to worry about as I have done a bit of research into previous tests with older rockets and chutes and I have seen videos of rockets and chutes that are up to 15 and 20 years old and they were deployed to see if it was still viable and they all still worked. OH&S is a rippoff in most cases it redtape crap gone mad and not sensible as usual govt bullsh*t is. This makes things overcomplicated and of course expense comes with that when realistically it doesnt ahve to be.

I have to confess its not all me doing this work on the RANS wings. I am not superhuman 😅 . I have great guy helping me get this done because I do have too many things happening at once here . I am very lucky to have him helping me get the wings done. Rodger wanted to have another project to do as he is retired and offered to give me a hand...of course I jumped at the offer. He has previously made a set of these same series wings for his aircraft, He is a master builder too. The previous aircraft a Waiex and RANS S-20 with the metal wing he has built are beautifully made. There is still a lot to do of course. The tail feathers and the fuselage will be delayed until I can get the new shed built here as all the other sheds have to be removed for the development of this block here at Burpengary. Mabel is almost ready to go to the hangar as soon as I can get the parachute install finished and that has to be done in the next week or three so the build shed can be cleared out to store all the stuff out of the first 2 of 6x9 sheds to be sorted and packed into boxes and stored in the 7x15 shed while the new 9 x 18 shed gets put up. Mabel will be moved to the hangar and the build table dismantled. Then all the gear will be stored in the 7x15 shed until the new one is up then the 7x15 will be taken away and the RANS will then be under way again in the new 9x18 shed...The house build at the farm should have its final inspection in about 2 weeks and the new shed up there hopefully will be erected in November, the concrete for the floor went down 2 weeks ago. That way all the farm gear will come out of the current hangar there and the hangar will be available for Mabel and the Mistress when she is finished.

22-09-23 Removed bottom RH wing skin and vacuumed swarf from cavity. Roller applied two coats of anti corrosion paint to ribs, stringers, spars and fuel tank supports. Deburred access cover ring tabs and clecoed in position on skin. Squared and leveled wing structure and refitted skin. 2.1h

EXC-3-185-C4-T (X-AIR Rotax 582 gear ratio 2.62) This is what you would require for your Xair

19/09/23 Match drilled leading edge of RH bottom wing skin to main spar. Removed clecoes and deburred bottom skin. Microstop countersunk main spar. Dimpled lead edge skin and re-clecoed skin to spar and ribs. 2.7h

Read the instructions for Eprop..they are the designers and manufacturers..they say pitch for 5500 WOT in level flight. This is where the prop is most efficient Setting it anywhere else you will obviously compromise the original design critieria. That drop off seems to be pretty large from my experience here with over 50 Eprop propellors fitted you must have a very high AOA on takeoff. most will climb at around 5200 to 5300 rpm when set to 5500 at WOT

Marty I doubt that very much...still have a lot of work still to get done on Mabel and the S-21. The problem is there isnt enough hours in a day now I am retired..its worse than when I had a real job. Between trying to get the house at the farm to a final inspection and the concrete went down for a new tractor shed up there last week also subdividing this block we are on here at Burpengary not to mention trying to get CDI modules and throttle kits made, things here at Burps will come to a grinding halt soon as I have 4 sheds to pull down and a new 9 x 18 mtr workshop shed to go up which will be the new build shed as well. The sheds have to go for the develoment of the block and a new shed put on a totally new alignment. I hope I live long enough to get it all done. 😩

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18/09/23 Inverted wing, leveled and squared structure on supports. Installed draw string for wing lights. Notched stringer around wing truss. Clecoed bottom skin to ribs to check aileron/flaps/tie down attachment penetration clearance. Removed skin and rolled edge break on leading and trailing edges. Trimmed skin around binding penetrations. Reinstalled and clecoed skin to ribs. 2.7h

15/9/23 Match drilled rear spar to upper RH wing skin. Removed skin clecoes and deburred rear spar. Trimmed and deburred aileron and flap wing gap seals. Aligned gap seals with upper wing skin profile and clecoed into position. Match drilled gap seals to spar and removed to debur. Refitted gap seals and riveted remaining rows to wing ribs. Riveted gap seals to rear spar. 4.8h

Oh yes she has many commands I must get done..she is still working so I am the gopher

Well I understand what you mean...been retired as such fr about 3 weeks and I need to go back to work for a rest

Savannah have a similar system on the firewall but use bowden cables one long and one short which of course creates issues with travel over each cable. Some have modified that to use 2 straight cables including myself. The rotating rod wears out over time. Most aircraft firewalls have other crap mounted on them. It was easier and more consistant to mount the whole assembly onto the carbs to tie them together and just use one throttle attachment. A couple of uys with savannah used my carb mount and use their bar on the firewall and use 2 rods with turnbuckles to operate my system. That seems to work fine as well so long as on a ring mount not a bed mount as the bed mount allows too much engine movement