Part 4 Slick 540

Sorry for the delay in updates. I have been getting a couple hours a day on it with slow progress. I have also been delayed due to change of plans and ordered some more wood. I will cover why later but it has to do with getting more throw out of my control surfaces. I also picked up the ne engine this weekend and will start trial fitting it.

Tail wheel installed.

Fine sanding to prep the rear deck

Cut out template for the sheeting

Cutting the sheeting to be vacuum glued onto the foam

Rear deck in the vacuum bag

Trimming the rear deck for the rudder area I used a hot knife.

Here is the rear deck installed.

I used cross threaded carbon fiber to re-enforce the rudder before sheeting. The sheeting will glue right over it.

Prepping the sheeting for the vertical stab

While the rudder dry's in the bag I started prepping the stabs. Here I used the dermal router to cut 1/8th inch deep into the foam for the plywood servo mount.

I also used the router to cut the balsa on the rudder and then pushed the hot knife through and cut the foam.

Gluing in the vertical stab using the laser level

Glued in.

Tomorrow I will sheet the stabs and prep the wings for sheeting.

Part 3 Slick 540

I tackled my first try at vacuum bagging and it went off with out a hitch.

The box part of the fuselage is complete and weight came in just under 3lbs so I am very happy with that especially with all the custom mods I did to strengthen that landing gear area and engine box up.

I have decided on using a different engine than originally planned. I was going to use a DA 120 but they shake so bad that I am worried with the hyperlite build I might shake the plane apart so I just ordered a GP 123 which I will break in on another plane for about 20-30 flights.

The canopy hatch is sheeted and the lower belly pan is in the vacuum bag tonight. Tomorrow I will cut some weight saving sections out of it using a router bit and a hot knife.

Sorry the video got cut short but I posted a picture of the vacuum bag with all the air removed.

Vacuum pump set at 5.5-6.5 lbs

I cut the bag and added the nipple

Air vacuuming out

Sheets taped and ready to cut to shape

Tracing the hatch onto the balsa

All the air is vacuumed out

Hatch is sheeted

This is the belly pan

The belly pan is the length of the fuselage so for shipping it's cut in half. I had to first join it together with epoxy and micro balloons

The wood is cut and ready to put resin on.

Its in the box foam ready

All the air is vacuumed out and will sit all night.



The box constructions of the fuselage is complete. Gussets, W, X, diagonal and balsa bone bracing is finished.

 

It almost looks like a plane now.

I got the sides into the jigs over the plans and mounted them to the engine box. I used titebond and CA. Then came the cross section. Here you must pay special attention that they are cut to fit precisely or your fuselage side will bow, bend in or worse banana shape. I admit I threw to the scrap pile more than 3 under cut ones. I soon learned start with the long ones so the short cuts can be used down the line. Once out of the jigs this is your first time to see if you really did build it all straight. I don't mind sasying, I did a hell of a job! Next came all the gussets. I am sure I am not the first to do this trick but I put about 5 at a time on a 3/8" piece of balsa and cleaned up the tab cuts on the bench disc sander (see pic)

I squared everything back up and turned the fuse over hanging the box off the bench. I used my Snap On chair, raised it up and put a rag between the plane and chair for a perfect soft, supported stool. Once the planes is weighted down level I put in the phenolic tubes and supports in place. I made sure the bench was perfectly level and then sighted everything thing up with the laser level. Then glued the phenolic tubes in place with 30 minute epoxy and micro balloons. This needs to dry until tomorrow and then I will cut the tubes and put those aside to be glued into the wings.





Slick 540 HyperLIGHT

ARF planes have lost their challenge and of course I need another plane because I have NO room for all the giants I have now.  But I found a challenge to fill my time. The 42% HyperLIGHT  Slick Edge 540 Starter Kit.

 

Short kit includes:

 

Full scale Cad Drawn Plans, Reference Sheets, Manual in PDF

 

CNC Router Cut Engine Box  

 

CNC cut Foam Wing, Vertical & Horizontal Tail, Front & Rear Deck and Lower Belly

 

Premium Vacuum Formed Canopy

 

Premium Fiberglass Cowl (2 Piece)

 

My goal is to keep this extremely light but strong with a finished weight of 27lbs and unlike most 40%ers that weight around 40lbs use a 170cc, this will use a 120cc

I am using ultra-light balsa from National Balsa and I’d like to point out they shipped the day after ordering, great service and very nice balsa. The wood to complete the plane will run you around $400.

The carbon fiber wing and stab tubes are from JTEC. The kit calls for TNT tubes which I did order from and have not heard from since so more on that later.

In the old days 30 years ago we used cement blocks for weight when sheeting the foam wings with epoxy for pattern planes that made the plane weight 100lbs it seemed like. But now we have better options so I will be using a vacuum bagging system that I am putting together this week and resin to sheet the wings.

So onto the build:

I have framed up the motor box. I did some weight savings by cutting out some wood from the firewall. Most of the box is framed up with CA other than the landing gear area I used 30 minute epoxy with micro balloons. The jig fit box is extremely strong and very well deigned to be light. It is very important to get the box square since the rest of the fuselage will be built off of it.

I was a little disappointed when I finished it because that’s it for pre-cut parts. Lots measuring and cutting from here on out.

 

First things first, start with the signature Spats.

The starter kit comes in five boxes of foam and fiberglass.

Un-boxed it all is packaged good and arrived un-damaged.

I removed some wood for weight savings from the firewall.

This is the motor box framed up. Everything gets jigged together and then wicked with CA.

Inside the motor box is lined with 3/8" triangle balsa glued down with CA. Plenty of cutting and sanding.

Clamps are a must and lots of them. This is the landing gear supports being glued in with 30 minute epoxy and micro balloons.

1/2" oak rails installed for the landing gear.

I use 3/4" angle aluminum attached to the bench for straight edges while framing up the side of the fuselage over the plans and wax paper.

Once the sides are framed I then sand them on a sanding board to clean all the glue joints. The board is 3/4" A Ply with 80 grit glued on to it.

A flat solid surface is a must of course so a new bench was in order.

 

It is not in the picture but sound board is placed on top of the bench to accept T pins.