Fiberglass demo

Host Bart Hull

August 9, 2003

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Members attending 17; Tom H, Marty, Ron Z, Kevin, Kyle, Rex, Merlin, Alan, Chuck, Neil, Owen, Gene, Ron W, Rich, Glen, John our newest member Tom ? and of course Bart. Bart started by discussing the power plant and modifications to it. Bart took the time to answer questions on each system of the power plant. There were to many to list here but I will cover some of the highlights. There is a pump that runs off of the cam on one side of the engine to provide vaccum for the various systems. The reduction unit for the prop and it's durability or hours of run time. The turbo charger and the modifications for this application. Most notible was Bart's creative use of kitchenware in the intake manifold. The center section was fabricated from a aluminum pot which fit the application very well. It was mentioned by other members that this can be a good source aluminum. Bart then moved on to the fuselage and its construction.
Rex's Harley parts
Railroad Switch Rail.
Discussing the engine
I believe the engine is an EJ-22 salvaged from a sedan. The turbo (not pictured is a Garret t-3) Eckenfelder intake manifold specially modified for high speed / high altitude cooking ala "Revere Ware", Stainless steel header was fabricated with a flange to accommodate the turbo. Subie-Lyc PSRU (Prop Speed Reduction Unit}, to the right front as pictured if one looks carefully they might see a pump connected to the camshaft (i.e. sticking out of the front of the right head). It is a little easier to see from the side however this pump provides the needed vacuum to run some of the other instruments in the aircraft. I believe the estimated HP was considerably higher at boost then Bart had planned on using. Whether this was coincidence or by design I recall something like 6psi boost and a little over 200hp is what the plane needed. This engine used in a rally car was pushing close to 400 hp.
Intake Manifold built from frying pans
Preparing the chemicals
Making some mention of the dangers of Methyl Ethyl Ketone Peroxide might be kinda cool. This stuff is not to be trifled with, it provides the heat needed during the curing process it's role here is as a hardener I believe.
Foam used to thicken and increase strength
Applying the outer layer
Not the first photo but the second, Bart is judiciously removing air bubbles from the recently applied outer layer. Bubbles cause a loss of strength in the bond and can help cause delimitation. This of course is not a good thing!
Progress on the airframe
Some of the Flight Controls
Interior of the airframe
Maybe make some mention of the fact that these are the antenna for the radio. Bart mentioned that this is possible to do with fiberglass but not if the airframe was composed of carbon fiber.
Right main-spar and ribs
While not pictured here it is worth mentioning that under some of these spars are "Knock plates". These are aluminum plates built into the wings interior surface, intended to help limit the damage from heavy handed refuelers. Also I am not completely sure of the concept but Bart mentioned this is a "Wet Wing" with both front and rear tanks. I believe this is to help balance the CG or Center of Gravity. I may be important to note that nose heavy planes fly poorly, tail heavy planes fly once. ( Bart, Rex and Gene had the conversation I was ease dropping ) Sorry guys but that's all I got. Just an idea but has someone asked Bart to proof the page and make additions? He may appreciate being asked and may also want to link our little page on his. Again, Please feel free to abuse this text in any way you see fit, these are just suggestions from my meager memory. :-)
Other fiberglass components
This is how it will look when completed.