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Old 08-05-2009, 06:14 AM   #101
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Re: 40% Carden Edge 540 - BBT - Build Thread


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Beautiful job trev. Where did you get the handy hot knife? I remember coring out pattern ships the same way. Took a lot of time but way worth it in the air! I think I will be putting together a 40% Carden Extra 300 next winter. Not going to the same extent as you but will be doing a few of your tricks.
Keep up the good work.
The NOIC is on August 22-23 right here in Sudbury. Hope everyone registers soon..gonna be a blast!

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Old 08-05-2009, 06:31 PM   #102
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Re: 40% Carden Edge 540 - BBT - Build Thread

Quote:
Originally Posted by yakityyak View Post
bore, cut, drill, slice, shave, sand, cut, cut, cut, crop, amputate, dock, ream, prune, skim, trim, file, decrease, eradicate, extenuate, jettison, mitigate, reduce, remove, thin, throw out



looking awesome, better then the builds I followed on FG, your doing awesome stuff here Trev, nice of you you share all your skill with us to learn from!!!!


COOL STUFF MORE CUTCUT
Wow! So many words! I'm going to try to use jettison, eradicate, prune and amputate through the rest of this build

Andrew, it's not about skill. It's all about patience (and my wife says I have non???)

There's nothing special here and anyone can do this! This build has taken me well over twice as long to get to this stage than normal, but I'm treating this more as a challenge for myself that just getting an airplane air-worthy!

If anyone has any suggestions or recommendations on what I could do differently or improve on, I'm all ears here. I'm learning a ton on this build!!!
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Old 08-05-2009, 06:38 PM   #103
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Re: 40% Carden Edge 540 - BBT - Build Thread

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Originally Posted by LEE View Post
Beautiful job trev. Where did you get the handy hot knife? I remember coring out pattern ships the same way. Took a lot of time but way worth it in the air! I think I will be putting together a 40% Carden Extra 300 next winter. Not going to the same extent as you but will be doing a few of your tricks.
Keep up the good work.
The NOIC is on August 22-23 right here in Sudbury. Hope everyone registers soon..gonna be a blast!

Lee
Hey Lee! Good to hear from you. I'm already booked for the Kingston fun-fly that weekend, so I'll have to pass on the Sudbury contest. Good luck with the event. From what I hear, you folks really know how to organize a top notch event!

Good to hear you are also going to do a Carden... soon you'll realize what you've been missing

As for the hot knife, when I recently ordered some unidirectional Carbon Fiber from "The Composites Store" (for the wings - details coming soon), I bought the knife. Here's the link for it. Best $40.00US ever spent !!!

The knife (29.99) + Power Supply (11.99) ---> http://www.cstsales.com/foam_factory.html
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Old 08-05-2009, 06:59 PM   #104
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Re: 40% Carden Edge 540 - BBT - Build Thread

I still find your builds even in summer amazing it would probably not happen for me.Enjoy your devotion to the lightest airframe possible. Good luck on the built.Don
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Old 08-05-2009, 08:47 PM   #105
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Re: 40% Carden Edge 540 - BBT - Build Thread

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I still find your builds even in summer amazing it would probably not happen for me.Enjoy your devotion to the lightest airframe possible. Good luck on the built.Don
Thanks for the compliments! With little kids, they head to be late enough to prevent me from flying during the week but early enough to get lots done on a build so I've found a special love for building as a result! (and my wife encourages it because I stay out of her hair )

Cheers

Trev
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Old 08-05-2009, 09:00 PM   #106
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Re: 40% Carden Edge 540 - BBT - Build Thread

Here's a few pictures of the hatch construction done. Total weight, minus the plastic canopy, came in at a scant 5.9oz thanks to the foam eradication (see Andrew -> I'm trying to use your words!!)
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Old 08-05-2009, 09:07 PM   #107
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Re: 40% Carden Edge 540 - BBT - Build Thread

Canopy was cut tonight. It took me 2 hours to get it exact, but I think it was worth it in the end!

And for the moment of truth -> If I follow a similar build on FG for a finished weight of 28.5lb, I needed the fuse and finished hatch to come in at 5lb 6oz.

Final weight came in at 4lb 11.5oz, so I'm 1/2 pound less than my target!

So....

If I go with a DA150, I'll finish the hatch interior and put in a pilot and panel (erasing this 1/2 pound) and shoot for a 31lb plane

If I go with a DA100L, I'll leave it as is and now shoot for a sub-28lb 40% !!!
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Last edited by TBrum; 08-05-2009 at 09:24 PM.
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Old 08-06-2009, 07:38 PM   #108
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Thumbs up Re: 40% Carden Edge 540 - BBT - Build Thread

Quote:
Originally Posted by TBrum View Post
Canopy was cut tonight. It took me 2 hours to get it exact, but I think it was worth it in the end!

And for the moment of truth -> If I follow a similar build on FG for a finished weight of 28.5lb, I needed the fuse and finished hatch to come in at 5lb 6oz.

Final weight came in at 4lb 11.5oz, so I'm 1/2 pound less than my target!
Trevor, that will be 10.5 ozs lighter, not 1/2lb, Even better, awesome job.
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Old 08-07-2009, 10:00 PM   #109
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Re: 40% Carden Edge 540 - BBT - Build Thread

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Trevor, that will be 10.5 ozs lighter, not 1/2lb, Even better, awesome job.

Good point Maqsood!!! Even better news
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Old 08-07-2009, 10:07 PM   #110
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Re: 40% Carden Edge 540 - BBT - Build Thread

Onto the rudder!

I'm always worried about the joint between the vertical stab and the fuse. I also wanted to reduce weight, so I decided to forgo the 1/4" crossgrain balsa here and went to 1/8" cross-g balsa with some unidirectional carbon fiber laminated on both sides.

I got the unidirectional CF from The Composites Store. The roll shown cost me about $100.00US (Should give me enough for the cored wings on this plane + a 43% with cored wings in the future!!)

Total savings over the stock design was 0.25oz, but every little bit counts, especially in the tail.
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