Notices
RC Pattern Flying Discuss all topics pertaining to RC Pattern Flying in this forum.

Zeus

Old 02-13-2018, 11:58 AM
  #1  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 424
Likes: 0
Received 1 Like on 1 Post
Default Zeus

There is still plenty of interest in IC pattern models. I looked at converting my Amadeus design but it is not really compatible. So a new design was needed to be powered by YS 200 or 50cc class two stroke. I'm calling it Zeus, Henry Piorun used the name but that was a long time ago so I am OK with it. The basic fuselage profile was designed in Autocad and is an Amadeus enlarged 15% in the height axis and then massaged into a final form. The fuselage area is a mighty 1100 sq. inches, bigger than the wing.
Attached Thumbnails Click image for larger version

Name:	Elevation.JPG
Views:	570
Size:	62.6 KB
ID:	2254501  
Old 02-13-2018, 12:08 PM
  #2  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 424
Likes: 0
Received 1 Like on 1 Post
Default

To give you an idea of the motor fit here are a couple of early versions with the YS and DA 50. As you can see there is also plenty of room for a couple of Tcans.
Attached Thumbnails Click image for larger version

Name:	Amadeus V2.JPG
Views:	416
Size:	39.7 KB
ID:	2254502   Click image for larger version

Name:	DA50.JPG
Views:	424
Size:	22.7 KB
ID:	2254503  
Old 02-13-2018, 12:50 PM
  #3  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 424
Likes: 0
Received 1 Like on 1 Post
Default

As usual this will be a molded fuselage. To produce the plug my method has been to transfer the profile onto a sheet of MDF. Glue expanded polystyrene to both sides and hot wire the top view then eyeball the rest. For this one I want to cut extruded foam slices on my CNC foam cutter and mount them on a length of rectangular section ali tube. This would require minimal sanding. I also get to look at the 3D version of the design as it needs to be modeled in a 3D CAD program first. I have recently moved over to Fusion 360 and spent some time getting to know it. This project was a good one to advance my CAD skills. It took a few attempts to work out a strategy in Fusion using the profile view from Autocad. I ended up doing it with 6 lofts, 2 rear fuselage, front fuselage, canopy, chin cowl and fin. I only lofted the right side of the fuselage then mirrored it for the left side. At the end of it my laptop was starting to struggle and it is no slug (8 core i7 16gb ram video card). Once I had the model I was able to massage the look and insert the motors to check for fit. The YS can move a lot rotationaly so was able to allow for that. The cowl may need a little blister to clear the exhaust during large excursions (backfires). Once I had it modeled I was able to work out where to cut the chin cowl and canopy hatches.
Attached Thumbnails Click image for larger version

Name:	fuller nose.JPG
Views:	351
Size:	67.6 KB
ID:	2254523   Click image for larger version

Name:	UC look.JPG
Views:	361
Size:	80.3 KB
ID:	2254524  

Last edited by RodneyFord; 02-13-2018 at 01:00 PM.
Old 02-13-2018, 01:40 PM
  #4  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 424
Likes: 0
Received 1 Like on 1 Post
Default

For most of the fuselage I am slicing it up into 95mm sections (100mm foam sheet less a surface skim). Fusion will output a drawing of each end of the slice for the foam cutter. Of course it is not as simple as that as the drawings need processing into the right format for the CNC foam cutter. This has been a learning curve too, but with the help of a few people in Germany and France I have it sorted. For each section 2 files are needed, one for each end. Fusion outputs these drawings which are a series of curves and straight lines. I open each one in Autocad and break the curves down into a series of short straight lines (this is automated). These get rejoined into a single multiline which is the path for the hot wire to follow. This drawing then gets converted (Profscan) into a data file that the CNC machine understands. However as each foam slice has a different drawing for each end they need further processing to make each end have the same number of line segments. This is a clever custom program called Echantillonnage it is in French so there was a fair bit of Google translate going on to learn it. The 2 files are then imported into the foam cutting program (GMFC) aligned and sized correctly then cutting can commence.
Here is a test piece but will end up as a 4 degree wedge at the tail post.
Attached Thumbnails Click image for larger version

Name:	IMG_0860.jpg
Views:	383
Size:	106.3 KB
ID:	2254543   Click image for larger version

Name:	IMG_0865.jpg
Views:	279
Size:	93.8 KB
ID:	2254544   Click image for larger version

Name:	IMG_0863.jpg
Views:	241
Size:	62.6 KB
ID:	2254545   Click image for larger version

Name:	X0.JPG
Views:	314
Size:	63.3 KB
ID:	2254546  

Last edited by RodneyFord; 02-13-2018 at 01:45 PM.
Old 02-13-2018, 03:20 PM
  #5  
flywilly
My Feedback: (121)
 
Join Date: Feb 2002
Location: glen allen, VA,
Posts: 2,263
Likes: 0
Received 30 Likes on 29 Posts
Default

Hi Rodney,
I will be watching with great interest! Technology sure facilitates complexity.
As for the name, Geez, how about Ares, the god of war? The Zeus was actually originally designed by a guy named John Nosler who then sold it to Henry. It is a fitting name... for what, I am sure, will be a superlative model!
Old 02-14-2018, 08:14 AM
  #6  
rm
My Feedback: (27)
 
rm's Avatar
 
Join Date: Nov 2002
Location: ohio
Posts: 554
Likes: 0
Received 0 Likes on 0 Posts
Default

i've thought of the 50cc before, but it's almost a lb heavier then a 33cc. Plus the pipe and header would prob be heavier.

Look forward to seeing how this turns out.
Old 02-14-2018, 02:02 PM
  #7  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 424
Likes: 0
Received 1 Like on 1 Post
Default

A battery weighs 1200gm a motor 600 Esc 100+ so that's at least 1900gm. My DA50 and ignition weigh 1560gm and know I can make a reasonably light custom header and can. For the airframe I can push the boundaries harder than commercial models so I am reasonably confident of making weight and have also designed in the lighter YS option. I want the weight to be as close to 5kg as possible and will size the wing/loading to suit. With the weight concentrated in the front I can move the wing forward for the longest possible tail moment.
Old 02-14-2018, 09:51 PM
  #8  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 424
Likes: 0
Received 1 Like on 1 Post
Default

Got most of the cutting files done. Cut out blanks and got into it. First time for this technique and I am pretty pleased with the result.
Attached Thumbnails Click image for larger version

Name:	IMG_0868.jpg
Views:	282
Size:	113.2 KB
ID:	2254736   Click image for larger version

Name:	IMG_0875.jpg
Views:	251
Size:	92.2 KB
ID:	2254737   Click image for larger version

Name:	IMG_0878.jpg
Views:	265
Size:	78.4 KB
ID:	2254738   Click image for larger version

Name:	IMG_0879.jpg
Views:	277
Size:	77.8 KB
ID:	2254739  
Old 02-15-2018, 03:19 PM
  #9  
MAVROS
 
Join Date: Jan 2009
Location: NEWCASTLE, AUSTRALIA
Posts: 342
Likes: 0
Received 0 Likes on 0 Posts
Default

Way to go Rodney........

I will be watching with great interest .


regards
Old 02-15-2018, 07:20 PM
  #10  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 424
Likes: 0
Received 1 Like on 1 Post
Default

More cutting. Working on the nose sections..
Attached Thumbnails Click image for larger version

Name:	IMG_0880.jpg
Views:	233
Size:	79.4 KB
ID:	2254811   Click image for larger version

Name:	Nose chop.JPG
Views:	305
Size:	102.2 KB
ID:	2254812  
Old 02-17-2018, 11:48 PM
  #11  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 424
Likes: 0
Received 1 Like on 1 Post
Default

More foam cutting. I will get this glued together now and can give it a sand. Doesn't need much. Just the cowl intake to shape by hand. Fin and canopy next.
Attached Thumbnails Click image for larger version

Name:	IMG_0893.jpg
Views:	253
Size:	86.6 KB
ID:	2255061   Click image for larger version

Name:	IMG_0895.jpg
Views:	300
Size:	77.5 KB
ID:	2255062  
Old 02-25-2018, 09:43 PM
  #12  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 424
Likes: 0
Received 1 Like on 1 Post
Default

Had a great weekend at IMAC comp flying my 42% Slick 360. Back into it, and cut out the canopy parts and glued them together with a bit of weight to hold it flat.
Attached Thumbnails Click image for larger version

Name:	20180225_141405.jpg
Views:	237
Size:	101.9 KB
ID:	2256178   Click image for larger version

Name:	IMG_0909.jpg
Views:	341
Size:	77.1 KB
ID:	2256179   Click image for larger version

Name:	IMG_0910.jpg
Views:	246
Size:	81.1 KB
ID:	2256180  
Old 02-26-2018, 05:54 PM
  #13  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 424
Likes: 0
Received 1 Like on 1 Post
Default

Attached a ply plate to the air intake and shaped it. Trimmed the canopy and fuselage cut out. Got it into the painting stand.
Attached Thumbnails Click image for larger version

Name:	IMG_0915.jpg
Views:	217
Size:	88.3 KB
ID:	2256284   Click image for larger version

Name:	IMG_0912.jpg
Views:	365
Size:	82.8 KB
ID:	2256285   Click image for larger version

Name:	IMG_0917.jpg
Views:	349
Size:	68.5 KB
ID:	2256286   Click image for larger version

Name:	IMG_0918.jpg
Views:	205
Size:	85.7 KB
ID:	2256287  
Old 02-27-2018, 08:12 PM
  #14  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 424
Likes: 0
Received 1 Like on 1 Post
Default

Spent some time fine tuning the fin. I use Profili pro for airfoils. I have SD8020 9.5% thick with the trailing edge thickened to 10mm at the root and SD 8020 12.5% thick trailing edge 10mm at the tip. Plenty of ribs to support the 3.2mm balsa sheeting.
Attached Thumbnails Click image for larger version

Name:	IMG_0921.jpg
Views:	217
Size:	89.2 KB
ID:	2256432   Click image for larger version

Name:	IMG_0923.jpg
Views:	211
Size:	94.4 KB
ID:	2256433  
Old 02-28-2018, 05:35 PM
  #15  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 424
Likes: 0
Received 1 Like on 1 Post
Default

Sheeted it with hard 3.2mm balsa. Attached the tail post to the fin then fin to fuselage. Fit is good.
Attached Thumbnails Click image for larger version

Name:	IMG_0926.jpg
Views:	233
Size:	94.0 KB
ID:	2256507   Click image for larger version

Name:	IMG_0928.jpg
Views:	220
Size:	87.8 KB
ID:	2256508   Click image for larger version

Name:	IMG_0931.jpg
Views:	381
Size:	50.6 KB
ID:	2256509  
Old 03-01-2018, 04:42 PM
  #16  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 424
Likes: 0
Received 1 Like on 1 Post
Default

Next up is lining the hatches. Put in some hard points so I can screw the hatches in place. I'm going to form the surface of the hatch with ACP (aluminium composite panel). Made a guide to cut out the Chin cowl.
Attached Thumbnails Click image for larger version

Name:	IMG_0932.jpg
Views:	193
Size:	75.6 KB
ID:	2256586   Click image for larger version

Name:	IMG_0937.jpg
Views:	211
Size:	87.0 KB
ID:	2256587   Click image for larger version

Name:	IMG_0935.jpg
Views:	190
Size:	75.9 KB
ID:	2256588   Click image for larger version

Name:	IMG_0936.jpg
Views:	308
Size:	83.5 KB
ID:	2256589  
Old 03-02-2018, 12:07 AM
  #17  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 424
Likes: 0
Received 1 Like on 1 Post
Default

200 gm glass, resin microfibres. We will see how it turns out tomorrow.
Attached Thumbnails Click image for larger version

Name:	IMG_0941.jpg
Views:	215
Size:	66.6 KB
ID:	2256610  

Last edited by RodneyFord; 03-02-2018 at 01:05 AM.
Old 03-04-2018, 01:39 PM
  #18  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 424
Likes: 0
Received 1 Like on 1 Post
Default

Making the tool to form the chin cowl base.
Attached Thumbnails Click image for larger version

Name:	IMG_0943.jpg
Views:	187
Size:	90.3 KB
ID:	2256853  
Old 03-05-2018, 02:09 PM
  #19  
Ricardo M.
 
Join Date: Jul 2003
Location: Montevideo, URUGUAY
Posts: 314
Received 21 Likes on 17 Posts
Default

Looks good. Congrats.
Old 03-05-2018, 08:22 PM
  #20  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 424
Likes: 0
Received 1 Like on 1 Post
Default

Thanks Ricardo. Would love to visit in Uruguay. Buenos Aries is a good way to come back from Europe to New Zealand, maybe next time.
Canopy lining and forming the radius to avoid stress risers. All this becomes time consuming. I want to be surfacing next week and I am hopeful that it will be quick due to the already good surface.
Attached Thumbnails Click image for larger version

Name:	IMG_0944.jpg
Views:	205
Size:	67.5 KB
ID:	2257820   Click image for larger version

Name:	IMG_0946.jpg
Views:	189
Size:	86.4 KB
ID:	2257821  
Old 03-06-2018, 11:17 AM
  #21  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 424
Likes: 0
Received 1 Like on 1 Post
Default

Nice clean fillets with minimal finishing required. The trick is going to be transferring this to the hatch cover with .5mm clearance.
Attached Thumbnails Click image for larger version

Name:	IMG_0947.jpg
Views:	217
Size:	58.0 KB
ID:	2257863   Click image for larger version

Name:	IMG_0950.jpg
Views:	255
Size:	58.2 KB
ID:	2257864  
Old 03-07-2018, 07:07 AM
  #22  
AmericanSpectre505
 
AmericanSpectre505's Avatar
 
Join Date: Mar 2007
Location: Fayetteville, NC
Posts: 1,238
Likes: 0
Received 1 Like on 1 Post
Default

I want one for a YS.
Old 03-07-2018, 05:36 PM
  #23  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 424
Likes: 0
Received 1 Like on 1 Post
Default

YS option. You will have to come and help mold one Bill. This a labour of love not money.
Attached Thumbnails Click image for larger version

Name:	UC adjustment.JPG
Views:	200
Size:	81.8 KB
ID:	2258028   Click image for larger version

Name:	UC look.JPG
Views:	208
Size:	80.3 KB
ID:	2258029  
Old 03-07-2018, 05:43 PM
  #24  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 424
Likes: 0
Received 1 Like on 1 Post
Default

I'm forming the base of the canopy hatch. To allow for some clearance I have heat formed some 1mm styrene and double sided taped it to the fuselage hatch cut out. I have some 4mm threaded rod to hold it in position while the epoxy cures. I use a layer of 200gm glass and a mixture of epoxy and microfibres to form the surface. I'm relying on the release agent to get it off.
Attached Thumbnails Click image for larger version

Name:	IMG_0952.jpg
Views:	227
Size:	64.7 KB
ID:	2258030   Click image for larger version

Name:	IMG_0955.jpg
Views:	178
Size:	74.7 KB
ID:	2258031  

Last edited by RodneyFord; 03-07-2018 at 05:45 PM.
Old 03-07-2018, 09:21 PM
  #25  
RodneyFord
Thread Starter
 
RodneyFord's Avatar
 
Join Date: Apr 2015
Location: Lower Hutt New zealand
Posts: 424
Likes: 0
Received 1 Like on 1 Post
Default

Got the glass and goop on. This has pushed up the front of the canopy hatch a little so it will need reshaping, all my good work undone. However I will treat it as a good thing as I can get more definition between canopy and fuselage.
Attached Thumbnails Click image for larger version

Name:	IMG_0956.jpg
Views:	180
Size:	80.2 KB
ID:	2258044   Click image for larger version

Name:	IMG_0957.jpg
Views:	204
Size:	83.0 KB
ID:	2258045  

Thread Tools
Search this Thread

Contact Us - Archive - Advertising - Cookie Policy - Privacy Statement - Terms of Service -

Copyright © 2024 MH Sub I, LLC dba Internet Brands. All rights reserved. Use of this site indicates your consent to the Terms of Use.