Lead (Pb) Feather (F) == Pizza Box Flyer (got it?)
Two weeks ago, I saw the Pizza Box Flyer (google LeadFeather PBF to get the plans) at our local indoor meet. It flew pretty well and this is going to be my next build.
Printed the tiled plans off and taped them together. The plans call for a 18" x 36" 6mm foam piece and my 6pmm depron was just short of it. So I ordered one off at rcfoam.com. To save on shipping charges, I ordered 10 sheets of 6mmEPP, 10 sheets of 6mm depron, 10 sheets of 3mm depron and the carbon rods (and a few extra for the future). The carbon rods are cheap vs. the LHS.
The foam was shipped today.
The foam arrived today by FedEx. Quick shipping by rcfoam.com
Today is Superbowl Sunday. I laid out the tiled plans on the table and taped them together. Let us see how much I can get done between now and Superbowl and my son's homework. The day looks good too so I might just go flying and start cutting later in the night after the game.
Went out flying for about two hours before the game. 60 acres was wet and muddy. My sons had a great time wallowing in the dirt. It was just a mess but beautiful though. Had one eye on the plane and the other on the sons. My six year old took a shot at flying Gene Bond's dome Blu and he did a great job. The plane is still a little tail heavy. Have to put a bigger battery to balance it. He also took a shot at flying the GWS piper cub which is a great plane anyway. He did his first take off today and it was good. No crash.
08/Feb/2010 (total time spent was 2.5hrs on all three cuts)
Lon Stumf, our local club president wanted to build a PbF too so he came by. Finally decided to cut three of them. One for my son, one for Lon and the third for my nephew in New Jersey. We have enough 6mm EPP from rcfoam.com
Cut up the plans using an exacto knife. It was nice to have the 3ft metal ruler from Harbor Freight. Take your time doing so i.e. measure twice, think three times, cut once and always have a sharp new blade.
Place the cutouts on the EPP and cut the EPP with a sharp new exacto knife.
For today, we just managed to cut out three top and lower panels. We then beveled the elevons and used welder's glue (available at Lowes) to hinge it. Bing/Goolge for youtube videos on how to hing with welders glue. It is pretty simple. When beveling, make sure to check which side you will be cutting. Not that it matters but it looks neat.
We then sprayed the lower KF panel with some 3M Super 77 Multipurpose Adhesive (available at most hardware stores in the US), aligned and placed it on the top panel and left it overnight with some light weights on it.
That was it for today.
09/Feb/2010 (total time spent 1hr includes managing the kids)
Kids wanted to paint the wing panels
This one was painted by my two year old with some final touchup by me. Ok, he insisted to paint it while his older sibling was at his paint job. This PbF will go to my nephew in New Jersey.
This one was painted by my 6 year old and will stay with us.
I also managed to cut up all the other pieces.
10/Feb/2010 (total time spent on all three 1hr)
Finished beviling the tail and the corresponding fuselage section. Screwed up one i.e. beveled the wrong side so had to cut up one more tail section from the scrap that was lying around. Used Welders Glue to create a hinge. Watch the following video.
I bought the Welder's glue at Lowes Hardware Store and it works very well. The hingle is pretty strong in about 1hr after which I went ahead and glued the fuselage to the body. If you look at the plan for the wing, it has markings for where the fuselage will sit. I traced that onto the wing, applied welders glue to the fuselage and slid it onto the wing. Make sure that the fuselage sits exactly in the center of the wing within the marked lines and it is at 90 degrees to the wing. Do whatever it takes to make it 90 degrees. In about 15 minutes it will harden and after that just leave it alone for the night.
While this was drying, I finished glue'ing the outer and inner skids using 3M 77. When doing so, make sure to keep track of the orientation of which side goes where. Place some weight on this so as to allow them to come in contact and dry straight and well.
12/Feb/2010 13/Feb/2010 (10 mins each)
Decided to glue in the skids. Used two reams of paper on either side to prop up the plane on its back (since the fuse was now glued in). Carefully aligned the skids and used welders glue to glue it down. Propped up the skids with whatever that had square edges on the table.
Next will to be complete all three. Since I do not have too many reams of paper, this process will have to be single threaded.
Next up will be to glue in the carbon fibre rod in the front.
Have been a little busy visiting the North West Hobby Expo in Monroe. It was a tame show but came out with some good deals on motors. In fact I bought a motor ESC combo from them for about $30 which is a little more than the price with Hobby King but I hope to complete atleast one of them this week4end.
Woke up with the mood to finish atleast one of the PbF's. Took me about 3 hrs of interrupted time to
- Add the servos (used 3 HXT 500's)
- Fashion a special mount for the motor. Used 3/8" poplar square dowel from Home Depot. Cut off the required amount and inserted it into the space between the nose and the wing and glued it using foam safe CA. I then cut off a square piece of aircraft ply, rounded the edges and glued that to the front and it became the firewall on which I will mount the motor.
- Add the motor and ESC
- Add the Receiver. I used the HobbyKing receiver.
The layout was all around the CG point. I did not have much of a problem with the CG. I just have one 450mah 2S Lipo and that too was just ahead of the CG point to bring the place correctly to the CG.
The elevons in the PbF were configured using http://blogs.hari.us/archive/2010/02/16/setting-up-elevons-for-an-rc-plane.aspx . Give the plane maximum throws on the ailerons and rudder.
The PbF is now complete. Maiden went off well. I did not have much in the way of throws so that was one thing that needed fixing. Here is the video.
other than the control throws, everything was perfect.
Completed the second PbF and this time around decided to do the maiden myself at 60 acres park in Redmond. Had ample space for mistakes and a lush lawn for landing. Took off smooth and handled beautifully. Next I let my 6 year old try the take off and he made no mistake. In fact he was bolder than me and took it for rolls and spins and it just worked like a charm. Finally ran out of juice and had to go home.