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Marty d's CH-701 build log


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Hey Marty, just catching up on your log, I noticed one deficiency in your ergonomics.While building a plane you often need the assistance of an extra set of hands.

Why not wear Harry's harness in front?

Why didn't I think of that?!?

 

 

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It worked!!!!!   I just popped the lower cowl out of the mould.  It came straight out, no sticking, no lumps and bumps and divots.  (Well maybe a couple of minor divots!)   Decided

Quick update - I finished trimming the lower cowl today (apart from where the exhaust will exit), located it properly and did a 1/8" hole on each side so I could cleco it.     Unfortunately

Step one is to cut your mat to fit the inside of the mould - lay the pieces out so you know whit bits fit which curves. Don't try to do the whole cowl with one big piece of mat. After applying ha

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Hi Marty,Well, the bare metal cost a bit over $5,000 freighted down from Sydney. I've probably spent another $2,000 or so on bits and pieces - picked up some Savannah fuel tanks, wheels, doors etc, and some stuff from Zenith in the US (gear/strut welded assemblies etc).

 

I don't know what the kit price is, but if you don't want to spend years producing what's in the kit, it's probably worth it!

 

Of course this doesn't include engine, FWF, instruments etc, but you don't get that in most kits either.

 

Personally if I was going to get something a bit cheaper than a kit or completed aircraft, I'd do what Mark (Kyle Communications) is currently doing - buy a damaged aircraft and do it up - http://www.recreationalflying.com/threads/my-savannah-s-model-rebuild-blog.156180/unread.

Most of the kit prices I,ve seen are between $40000-$60000 airframe only so quite a saving but the time factor difference is big. cheers

 

 

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  • 4 weeks later...

Done some work on the rear fuselage bottom - drilled & clecoed longerons, L-angles, Z-channels, main front channel. Have to unpeg it from the bench now to do the front longeron doublers.

 

That big hole is the rear access hatch, used either for checking/adjusting the flaperon mixer, or transporting a stowaway. W&B may be an issue for the latter.

 

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I swear - I only buy them because they're the cheapest in the paint shop....

 

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Z supports around the hole

 

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Front channel with doubler for torque tube

 

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Marty, stop it!

 

You are getting ahead of me again. I promised myself that I'd get my Lightwing in the air before you finish the 701 !

 

Every time I see you post another step forward, I seem to discover another unforeseen setback. Feels like I'll never get it done! At this rate you're going to beat me, and I started with a complete aircraft!

 

 

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Have no fears on that score Pete. Whenever I think about everything that needs to be done to get this bird in the air I almost have a heart attack. I plan to retire in 15 years, wouldn't be surprised if I get the plane finished on the same day...

 

 

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Marty, stop it!You are getting ahead of me again. I promised myself that I'd get my Lightwing in the air before you finish the 701 !

Every time I see you post another step forward, I seem to discover another unforeseen setback. Feels like I'll never get it done! At this rate you're going to beat me, and I started with a complete aircraft!

Ah, but Marty lives in Tassie where he can only fly on good days (twice a year), you live in SEQ where there are only two crappy days a year. It might take a bit longer to build, but you'll have more flying once it's done.074_stirrer.gif.5dad7b21c959cf11ea13e4267b2e9bc0.gif

 

 

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Gee thanks, I feel so much better now. I'll just go right out into the 50 degree heat and sweat some more.

 

Marty, it's easier to see what you have to do because you are starting with nothing and building everything with new materials. In my case I started with an aircraft that looked like it didn't need much work, until you pull any item off to inspect and then discover that it is either stuffed from the inside out, or has been mentioned in a Service Bulletin and Must be replaced. eg, the Rotax oil tank turned out to be alloy which, unbeknown to me, should have been replaced ten years ago with a Stainless Steel one ($1100 thanks), then I discover that Lightwing had modified the alloy one in a way that I couldn't copy. So then I had to cut a hole in the cowling to get access to the dipstick, and make a hinged hatch for it. And on it goes. King Midas in reverse (everything I touch turns to shyte) but now I am getting used to it and have grown ever more determined to finish.

 

Problem is, once I do get it finished (if I ever pluck up the courage to test fly it), I'd like to take it home to Tasweigia. BUT the Home Control Manager has forbidden me to fly it over water. I keep telling her that water is so much softer to crash into than mountains, but does She listen?

 

Anyway, by then Marty should have noticed that his driveway is a bit short for even a CH701, and moved to a flat place with room for a little Lightwing to keep his plane company.

 

 

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So take the wings off and trailer it on the Spirit Pete. Everyone's happy and you get to spend the evening in a comfortable bar!

 

If you find a nice flat field I'll happily have my 701 cohabit with your Lightwing. Mind you, where you'll be living you have a custom made lovely flat runway right in front of you - all you need are floats!

 

 

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Over the last week I've prepped and riveted the bottom skin structure (except for the longerons, which apparently shouldn't be riveted until the side holes are done).

 

Also cut out the two side sheets. This is getting exciting... can't wait to have a fuselage sitting on the bench!

 

Received my nutplates today, tested one on a piece of scrap. I need to get some #40 pop rivets - I thought I'd use solids but they're too hard to press on the back bit where the nutplate gets in the way. Then I can make the bottom hatch and put it on, not to mention a couple of inspection plates (at least) in each wing. Oh, and the elevator trim servo. Bugger - I hope 50 is enough!

 

 

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Have no fears on that score Pete. Whenever I think about everything that needs to be done to get this bird in the air I almost have a heart attack. I plan to retire in 15 years, wouldn't be surprised if I get the plane finished on the same day...

That is the most negative comment I have ever seen you make Marty. Because this is so out of character, my assumption is that you are planning to finish it ten years before your retirement. 003_cheezy_grin.gif.c5a94fc2937f61b556d8146a1bc97ef8.gif

 

 

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  • 3 weeks later...

I've been spending a few hours mating up the bottom of the rear fuselage with the rear sides. I pre-drilled the sides together and I'm incorporating diagonal L-angles as well to minimise oil-canning.

 

Also fitted the nutplates around the bottom hatch and screwed the hatch cover on, but not entirely happy with the fit - the diamond bends in the hatch curve the edges and leave a few gaps around the perimeter when it's screwed on. How's the fit with other 701's? I'm thinking of replacing it with a flat hatch cover with internal L-angle stiffeners.

 

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  • 5 weeks later...

Haven't posted for a while (about this, anyway!) but have been doing a bit between jobs around the house.

 

I've completed the top and internal L angles. Weighed the extra diagonal bracing, the aluminium is only 212 grams so I think it's worth doing.

 

Also have been deburring and drilling out to final rivet size as I go, so should make it easier to get to riveting stage. After that I really need to work on a new workspace which allows me to get in and out of the fuse!!

 

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  • 1 month later...

Pulled a few hundred rivets recently and got most of the rear fuselage done. I was taking some snaps of it this evening and wondered what it'd look like with the tailfeathers in position...

 

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You're running out of room to walk (work) around your project. It's outgrown it's space!

 

Looking more like an aircraft every time we see it. Well done.

 

 

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... and another milestone reached ...

I like the way that Marty's ceiling has been sponsored by Bunnings Corporation (BC).

 

Perhaps BC will sponsor an extension too?

 

 

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I like the way that Marty's ceiling has been sponsored by Bunnings Corporation (BC).Perhaps BC will sponsor an extension too?

Now you're thinking 80kts. Wesfarmers (owners of Bunnings) made about $10 billion over the last 5 years - surely they can throw a few thousand my way for advertising services!

 

 

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  • 2 months later...

Rear fuselage - finished!

 

Another big riveting session on Wednesday and the structure of the rear fuselage is complete. There are some bits left to rivet, but these are best left until after the control hardware, like the flaperon mixer, are installed behind the seat back.

 

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Complete rear fuselage. The large flat section clecoed to the front is the seat back.

 

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Just like the picture in the instruction book!

 

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Looking back along the top.

 

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Baggage compartment and seat back. The slots at the side are for the flaperon pushrods. Looking at the interweb, many people put a shroud around that after controls are installed, which would keep baggage from fouling the rods - perhaps a good idea!

 

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Underneath the baggage compartment, looking backwards.

 

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Rear wing mount - this bolts to the rear spar.

 

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Top seat belt mount (sash part for lap/sash).

 

 

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Rear fuselage - finished!Another big riveting session on Wednesday and the structure of the rear fuselage is complete. There are some bits left to rivet, but these are best left until after the control hardware, like the flaperon mixer, are installed behind the seat back.

 

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Complete rear fuselage. The large flat section clecoed to the front is the seat back.

 

[ATTACH=full]51544[/ATTACH]

 

Just like the picture in the instruction book!

 

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Looking back along the top.

 

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Baggage compartment and seat back. The slots at the side are for the flaperon pushrods. Looking at the interweb, many people put a shroud around that after controls are installed, which would keep baggage from fouling the rods - perhaps a good idea!

 

[ATTACH=full]51547[/ATTACH]

 

Underneath the baggage compartment, looking backwards.

 

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Rear wing mount - this bolts to the rear spar.

 

[ATTACH=full]51549[/ATTACH]

 

Top seat belt mount (sash part for lap/sash).

When I view your picture ("Underneath the baggage compartment, looking backwards"), I seem to see a light at the end of the tunnel.

 

I hope you can too!

 

 

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Thanks guys!

 

What amazed me was how light and rigid it is. I easily carried it from the work bench through to the store room (its current resting place is on two bed bases). As soon as that rear baggage wall went in, all the flex was taken out of the structure.

 

Now I'm getting concerned about the amount of A4 (1/8") rivets left... I've gone from a 4L ice cream container full down to about a cup left. Got plenty of A5's though (5/32"), and I think most of the front fuselage uses those.

 

 

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Thanks guys!What amazed me was how light and rigid it is. I easily carried it from the work bench through to the store room (its current resting place is on two bed bases).

I can see you carrying it into the office Monday morning; "Hey guys, look what I did on the weekend!" 012_thumb_up.gif.cb3bc51429685855e5e23c55d661406e.gif

 

 

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