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Post by krmckay "Bombs away" on Apr 24, 2021 10:07:56 GMT -4
Just before lock-down I was doing more research on 3D printing an airplane. I have already printed a YAK55 but found errors and faults in the design that would not make it airworthy and now have aborted the project. I sat down and did alot of online research from several RC/3D sites and found the plan for the Liddle Stick. No longer available on Thingiverse but still available on Cults3d.
I trialled printing a few parts that turned out not so good I was lead to several unknown features in my 3d Slicer I never knew existed. With this new knowledge under my belt I have begun printing out the entire plane with excellent results. The fuselage is fully printed now and I'm beginning on wings. it will still take me more than a week to finish the printing before assembly can begin. Double wall and proper infill levels are key to this build. I have to custom edit every part in the slicer, hence why the printing is taking so long. some sections of the wings take over 20 hrs to print. I haven't added up the total print time yet but I think I'm looking at easy 100+ hrs to print out all the parts. (not accounting for filament breakage TWICE). I was 90% thru one section of wing when the filament broke with 1 hr remaining. Of course I had just checked the print progress just prior to the break, and wasn't able to salvage the print job. so that wasted an entire day except it proved the print would have been structurally strong and definitely airworthy.
I'm hoping the All up weight will be light enough for the motor I have planned for it. Racestar BR2826 1290 kv. I've been playing with the infill to balance structural strength against weight of components. I've found that triangle infill is the best for structural strength but infill percentage must be as low as possible for weight. I have been weighting every part as it comes off the printer and the weight is about 10% lighter than the estimate in my slicer (Cura). The fuselage is just over 320 grams, I estimate each wing half will come in just over 500 grams. The weight will be more than I want so I may have to upgrade the motor and ESC to meet the needs of the plane.
More to follow as the build progresses
Al (Astroflyer) I will be taking photos of the build once I have more parts printed out and assembly begins.
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Post by astroflyer on Apr 26, 2021 14:40:23 GMT -4
Thanks Kevin. I look forward to those photos! Al (Astroflyer) I will be taking photos of the build once I have more parts printed out and assembly begins.
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Post by krmckay "Bombs away" on Apr 26, 2021 15:19:25 GMT -4
It's going to be a long process to print all the parts ...at least another week based on two parts per day,printing 20+ hrs per day.
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Post by astroflyer on Apr 26, 2021 20:03:41 GMT -4
No worries Kevin. I'll be here. lol
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Post by mailman on Apr 28, 2021 22:43:01 GMT -4
Following your progress to see how it turns out. This one's on my bucket list to print when I get some free time to tweak the printer and Cura settings.
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Post by krmckay "Bombs away" on May 1, 2021 9:47:22 GMT -4
I'll try and get a few pics up later today. I'm about 3/4 finished printing all the parts. Only one section of wing left to print before wing assembly. Painting the graphics on PLA SUCKS as the paint wants to run and follow the seams. I'm currently re-printing the fuse again with a 3 layer skin vice the previous 2 layer, just to make the fuse a little more rigid. Based on current weight of sections I've gone out yesterday and ordered online an upgraded motor and ESC to make sure it has enough power. I'm estimating the AUW of the plane will be in the 4 pound range and that means I'll need a 300-350 watt power plant to pull it thru the sky.
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Post by krmckay "Bombs away" on May 1, 2021 10:53:08 GMT -4
Here are a few pics of the parts printed and painted, all gray parts are being reprinted with 3 wall version for added rigidity.
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Post by krmckay "Bombs away" on May 1, 2021 10:57:34 GMT -4
The first pic above shows the iron cross I'm trying to paint on the wing segment...don't look to closely as it is still a work in progress and I have already had to over spray that section in white and start again. The left wing that is laid out has not yet been glued together, its just showing what the left wing will look like if I ever can get a good iron cross painted on it.
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Post by krmckay "Bombs away" on May 3, 2021 21:21:52 GMT -4
Based on projected all up weight I've decided to purchase another motor(s) and ESC to power this project. I've purchased 2 x D3530 1100KV (313w) and a 1400KV (446w) plus 2x 50 amp ESCs to ensure I have the power for this to fly. Wings are printed and fuse is 1/2 re-printed with 3 layer walls to increase overall strength. elevators and 1/2 of the ailerons have been printed along with vert and hortz stabs. soon will be finishing the paint and assemble will begin...maybe by end of the week. My next big decision is Futaba or Spektrum system. If I go Spektrum I will have to purchase a full range receiver, as for Futaba I have several. Hummmm?
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Post by krmckay "Bombs away" on May 9, 2021 21:12:57 GMT -4
Well all components are now printed including a lot of the hardware. If this plane is going to be a 3D printed plane then so are all the bolts and nuts. I just finished printing the M6 bolts and 1/4x20 bolts that hold the engine mount/battery tray/landing gear and forward fuse F1 and F2 all together (other than the glue). it is slowly starting to look like a plane. I've 3D printed everything except the electronics...unbelievably it is strong and weights in at just 2.03572 KG as weighted by individual components prior to installation (just missing battery weight). I can't wait until the motor, receiver and ESC get here later this week. I've decided to go Spektrum for the radio system. I'll be installing an AR410 receiver with telemetry and my Spektrum 7S transmitter along with an EP-Power D3530 1100KV or 1400KV motor with a Flycolor FlyDragon Lite 50A 2-4S Brushless ESC. with 313 to 446 watts of power respectfully from those motors using a 3S 2200Mah battery and I have a couple spare (NEW) 3300mah batteries in reserve if needed. More than enough power to pull this thru the air. Never too much power !!!
I still need a carbon fibre spar to install in the wing and that might have to wait until the lockdown is lifted to acquire.
More updates coming as parts arrive.
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Post by krmckay "Bombs away" on May 11, 2021 18:11:27 GMT -4
Here is a test of my new online storage for photos of this build...let's see if it works :
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Post by krmckay "Bombs away" on May 11, 2021 18:13:13 GMT -4
It's working perfectly ...now I can upload all the high Res photos I've taken so far of this build with more to come as assembly progresses.
One major note of wisdom DO NOT print bolts out of PLA filament. I attached the landing gear temporary to the fuse to test assembly and tighten the bolts only finger tight...as I sat there doing other gluing of items there was a pop and a bolt head whizzed by my head. 5 mins later a second went flying. Yesterday I reprinted the 1/4 x 20 bolts in PETG with much better results and thinking about this last night I'm in the process of re-printing the landing gear in PETG and reorienting the print so layers run inline with the gear legs and not cross ways. One good landing and the gear would probably have snapped off.
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Post by Bill F on May 11, 2021 23:03:44 GMT -4
Terrific pictures Kevin, pretty bad when you have to wear a hardhat while sitting at the bench..LOL!
You sure are learning your new trade..exciting days ahead..!
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Post by krmckay "Bombs away" on May 12, 2021 9:54:50 GMT -4
Landing gear and all bolts re-printed and temp installed until the motor and ESC gets here (later today or tomorrow according to tracking #)...shame that it took a week to get to Canada from China but 4 days to get from Halifax to my mailbox via Dartmouth (if delivered tomorrow). I'm pretty much at a stand still until the electronics get here. Receiver will arrive Thursday according to Amazon tracking. I had to order the main wing spar yesterday from Amazon (via China) as couldn't find a 10mm carbon fibre tube locally, but I'm not ready for that yet as the wing is only partly assembled so far.
No need for a hard hat now!
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Post by astroflyer on May 12, 2021 12:09:23 GMT -4
What an interesting and fascinating project Kevin. Thanks for all the info and photos. Look for a good spread in the June newsletter!
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Post by krmckay "Bombs away" on May 13, 2021 15:21:53 GMT -4
Hang on there Al. I'm not even 1/2 way finished the build.. Motor ESC and receiver just arrived an hour ago and I'm hot into binding the transmitter to the receiver and checking out all the telemetry setup.
More photos and write-up to come over the next couple days.
FYI some of the photos have comments on them explaining what you are looking at so don't miss them.
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Post by krmckay "Bombs away" on May 13, 2021 19:06:20 GMT -4
More pics uploaded. Fuse is coming together with F1/F2 now glued to F3/F4 (drying now). Receiver, ESC and motor(s) now in the pics. I have two options for motors Ep-Power D3530 1100 KV and a 1400KV. See the comments on the pics for more details.
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Post by astroflyer on May 14, 2021 13:20:48 GMT -4
No hurry Kevin. I won't be putting this together until the end of the month. You didn't think I was more organized than that did you? lol
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Post by krmckay "Bombs away" on May 14, 2021 19:34:21 GMT -4
By the product you produce I did think you were on top of all things RC in the Zone!!!
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Post by krmckay "Bombs away" on May 14, 2021 19:40:49 GMT -4
Had to make a trip to Mighty Small cars this afternoon for Bullet connectors and machine screws to connect and mount the Esc and Motor. I've decided to modify the motor mount with offset but have to wait for 3D printer to finish another project for my son. The biggest delay is waiting for the wing Spar to arrive from China as no one had a 10mm x 1000mm Carbon fibre tube locally. It should be here by Tuesday (coming Fedex).
Progress is happening but not as fast as I would like.
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Post by krmckay "Bombs away" on May 15, 2021 14:51:30 GMT -4
Eight more photos uploaded showing motor mounted with ESC and Receiver installed. Motor run-up completed to ensure correct rotation (without prop for safety). Wing fitment completed, just waiting on Wing Spar to arrive Tuesday before completing wing panel gluing. Still have Hortz and Vert stabs to glue on F5 and F5 to attach to the remainder of the fuselage. Then flight control surfaces will be next.
Note on the close up of the motor that I have replaced the motor mount with a black printed one that has 1.5 deg right and down thrust correction. If I find that I don't like that I can print a straight one in an hour and replace it.
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Post by krmckay "Bombs away" on May 16, 2021 14:12:54 GMT -4
Seven more photos added. F5 was glued to the Fuse last night and the Hortz stab was attached this afternoon......Boy measuring 7 times and gluing once is time consuming. All is square and straight.
If you notice I have inserted Bamboo skewers and toothpicks through the fuse into the Hortz stab for added structural strength and insurance to hold everything straight while the glue cures. The Bamboo will stay the length they are for the same reason when the Vert stab is attached. the toothpick (centre piece of wood in the photos)will be shaved down as it is not required for the vert stab.
Here is another copy of the link to the photos so you don't have to scroll to the top to find it.
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Post by krmckay "Bombs away" on May 18, 2021 14:30:33 GMT -4
Four more pics uploaded today. Carbon fibre tube arrived today as I was working on assembling ailerons and elevator. Rudder was installed and CA hinges pinned last night (I don't trust CA Hinges). Just finished gluing wing panels and fitting the wing spar. I'm getting closer to saying done.
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Post by sandy69 on May 18, 2021 15:07:58 GMT -4
Based on projected all up weight I've decided to purchase another motor(s) and ESC to power this project. I've purchased 2 x D3530 1100KV (313w) and a 1400KV (446w) plus 2x 50 amp ESCs to ensure I have the power for this to fly. Wings are printed and fuse is 1/2 re-printed with 3 layer walls to increase overall strength. elevators and 1/2 of the ailerons have been printed along with vert and hortz stabs. soon will be finishing the paint and assemble will begin...maybe by end of the week. My next big decision is Futaba or Spektrum system. If I go Spektrum I will have to purchase a full range receiver, as for Futaba I have several. Hummmm? Fruitbar of course. Great project Kevin, keep us advised sir.
Feeling blessed that your shop looks almost as clean as mine.......
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Post by krmckay "Bombs away" on May 18, 2021 16:26:35 GMT -4
Thanks for that vote on cleanliness there Sandy...I just don't know where I'm going to put my second 3D printer. I've ordered an Ender 5 PLUS capable of 350x350x400mm printing, almost twice my Basic Ender 5 machine. I'll be busy on Saturday once it arrives setting it up and testing it out. I've maxed out all the upgrades I can do to the Ender 5 and looking forward to doing the same to the Ender 5 PLUS.
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