Author Topic: Composite Fuse E-Pathfinder (Read 2890 times)

Jeff Traxler · « **on:** October 30, 2011, 08:02:34 PM »

ECLPA Fans,
If the pictures take I will share details............

Jeff Traxler · « **Reply #1 on:** October 30, 2011, 08:15:50 PM »

Here we go again.....

Jeff Traxler · « **Reply #2 on:** October 30, 2011, 08:49:40 PM »

OK,
This is the reason my E-Slob is taking so long.After converting an ARF Pathfinder to E-power and flying it is when I decided to go E-Power for most everything.The first factory fuse was JUNK.The ply doublers delaminated from the lack of glue and the nose(leading edge forward) came off after a Buckhorn snag.I reglued it but it never flew the same.I got another ARF Pathfinder in a trade and that fuse was the same way.It was so crappy you could twist it 30 degrees in each direction.I decided to build a new fuse just for E-power.The construction is similar to Crist's built up designs except I used a Warren truss pattern instead for the rib structure.The rib material was 3/32 balsa covered on both sides with .05 carbon mat.I layed up a piece of sheet on both sides and ripped it to width after it cured and used that for rib stock.The 1/16th balsa skins were first layed up with .05 carbon mat on the inside and then applied.All the final shaping was done after that and then the small 1/64 ply doublers were feathered out on the edges and applied.Then the entire fuse was covered with carbon mat and 2 Oz. glass from the T.E. forward.All the extra work over a conventional construction built up profile was well worth it.All the carbon paid off bigtime as far as the twisting and weight goes.This fuse is as stiff as most any built up fuse and ended up weighing 31 grams less than the factory fuse out of the box.I got to do a few test hops today and it shows real promise.I have to do a couple trim things and take it from there.The next outing I will try to get lap times,MaH usage ect. and post it here.Jeff

Crist Rigotti · « **Reply #3 on:** October 30, 2011, 09:25:29 PM »

Nice job, Jeff!

Wynn Robins · « **Reply #4 on:** October 30, 2011, 10:56:28 PM »

I was wondering where the composite part came from.....looks good.....

Jeff Traxler · « **Reply #5 on:** October 31, 2011, 12:32:51 AM »

Hi Wynn,A composite is created when 2 layers of carbon,fiberglass,Kevlar or similar are epoxied on both sides of a core material.It can be foam,balsa,flat carbon strips laminated to the top and bottom of a spar.The seperation of the 2 E-glass/carbon layers by the core(whatever it is)determines the strength.Example:If you take 3 pieces of foam 1/8,1/4,and1/2 and laminate both sides of each piece with the same amount of material,the thinner the core is the weaker the piece will be structurally.All 3 will be way stronger than just the foam itself but the 1/2 wil be strongest of all.I just did a wet layup on mine but the sheets could be vaccum bagged for additional weight savings.Wet layup on foam was how the homebuilt composite movement got started.The Vari Eze,KR-! and 2,War Aircraft Replicas,and more were carved foam and wet layup E-glass.It does not have to be popped from a mold to be composite but it sure is easier that way.I am working on some molds for this winters main project.We're gonna try that next.
Jeff

Derek Barry · « **Reply #6 on:** October 31, 2011, 04:46:44 AM »

Looks good and strong Jeff!

Derek

Jeff Traxler · « **Reply #7 on:** October 31, 2011, 12:03:43 PM »

Hi Guys,Thanx for the kind comments.There are a couple other things I have done to make this a unique project.When I was constructing the inner core of the fuse I made it so the faux scoop on the front was actually a working scoop channeling cooling air right to the back of the ESC so it is being cooled on both sides.I also picked up a heatsink that they use on R/C cars and attached it to the back of the ESC thus sending the channelled air right through the cooling fins further adding to the cooling.I usually try to touch the components after every flight to check to see if anything is getting too warm and this ESC was the coolest by a longshot.The Novak heat sink is extruded aluminum,cost less than 5 bucks and only weighs 7 grams.I have spent many,many hours with very high end sound reinforcement systems and cooling was always a concern.Simple forced air will keep most any electrical component working better and more efficient.This is the simple logic I used for the scoop and heatsink and so far it seams to work very well.I hope to get out Tues. or Weds. and fly it some more after making a couple trim adjustments and I will let ya's know.Jeff

Wynn Robins · « **Reply #8 on:** October 31, 2011, 04:08:00 PM »

Quote from: Jeff Traxler on October 31, 2011, 12:32:51 AM

Hi Wynn,A composite is created when 2 layers of carbon,fiberglass,Kevlar or similar are epoxied on both sides of a core material.It can be foam,balsa,flat carbon strips laminated to the top and bottom of a spar.The seperation of the 2 E-glass/carbon layers by the core(whatever it is)determines the strength.Example:If you take 3 pieces of foam 1/8,1/4,and1/2 and laminate both sides of each piece with the same amount of material,the thinner the core is the weaker the piece will be structurally.All 3 will be way stronger than just the foam itself but the 1/2 wil be strongest of all.I just did a wet layup on mine but the sheets could be vaccum bagged for additional weight savings.Wet layup on foam was how the homebuilt composite movement got started.The Vari Eze,KR-! and 2,War Aircraft Replicas,and more were carved foam and wet layup E-glass.It does not have to be popped from a mold to be composite but it sure is easier that way.I am working on some molds for this winters main project.We're gonna try that next.
Jeff

I understand what composite is HA

......I was just meaning that your fuse looks like a standard one - so was wondering where the composite side of it was.....as far as - your title said composite fuse - but the pic shows a finished one where you cannot see the composite structure - it looks good by the way. (again)

Paul Taylor · « **Reply #9 on:** October 31, 2011, 05:07:46 PM »

That is way kewl Jeff. Dennis V always kick butt with his but with IC. This should be a killer combo.

Dennis Adamisin · « **Reply #10 on:** October 31, 2011, 09:30:11 PM »

GREAT job Jeff, this one should serve you well!

Ward Van Duzer · « **Reply #11 on:** November 09, 2011, 09:30:30 AM »

Great job of engineering! You solved a couple of my E-Force "problems".

Thanx!

Ward

Jeff Traxler · « **Reply #12 on:** November 09, 2011, 10:52:34 AM »

Dennis,
This is the one I was telling you about at the Signal Seekers.So far so good.This one is no comparison to the stock fuse versions.The rounds are smooth and this turns tighter than any stock Pathfinder I have flown so far,Electric or IC.After all the flights I have flown on it so far I feel the components and the scoop/heatsink combo for the ESC I incorporated into this design is performing FLAWLESSLY.The ECS is hardly even getting warm and the battery and motor have the usual warmth.I like the headroom with the 5s packs and this one has plenty of GoNads to spare!!!

Ward,
Thanx for the complements.I tried to make it light,strong,and very rigid for the best performance and all the flights so far are exceeding my expectations.This will be my profile ship of choice for competition next year.If you ever have any questions please feel free to ask and I will answer them ASAP.Fly-E,Jeff

Jeff Traxler · « **Reply #13 on:** February 05, 2012, 01:04:44 PM »

Hi Everyone,
I have about 50 flights on this now and it is pretty dialed in.I put 4 more on it this morning in cool but very favorable conditions with a steady light breeze of about 5 MPH.It performs well with the battery usage being what you would expect.For someone on a budget my CHAS setup works well.(CHeap Ass System).
No Name 35-48-800Kv off Ebay $10.00 Shipped
Zippy 2650 5s 40c batteries $35.00 " from US
Hobby King 40 amp ESC $25.00 " " "
Hubin FM-0C TIMER $15.00

I have been using CHAS to learn the ins and outs of E-flight and after just moving up to Intermediate and the rest of the pattern last summer this will take me to the next level.I'm comin' to get ya Hudak!!!!

Trax

Bob Hudak · « **Reply #14 on:** February 05, 2012, 08:34:37 PM »

HaHahaha

Ok you got my attention Jeff. But whilst you were sleeping I have been burning the midnight oil to have this years electric powered stuntship ready for spring training. Only need to put a little more trim work(bling) on the fuse then I'll snap a few pics and post em',should be done before this weekend. Are you still planning to go to Brodaks? I could use your experience in the snake pit! Nice job on the PathFinder by the way.

Dennis Adamisin · « **Reply #15 on:** February 05, 2012, 08:35:26 PM »

IMPRESSIVE! i think set-ups like yours are at least as good as a good IC system - plus you have the absolute repeatability that lets you concentrate on flying.

Jeff Traxler · « **Reply #16 on:** February 05, 2012, 11:59:05 PM »

Hey Bob,The plan is to be there this year.I look forward to all the escapades that week will bring in the campground

I'm sure I'll talk to you before then.

Dennis,That is the red El Cheapo motor I showed you at the Signal Seekers contest.It nosed over on a earlier flight and kicked up a little dirt before shedding the prop.My helper hit the panic button pretty quickly and no damage happened.I blew out the motor and put on a new prop and it has'nt phased it at all.I want to try one of the new wide blade props with a little clipped off the tips.I'm in for a half dozen when they are available.
Jeff

Howard Rush · « **Reply #17 on:** February 06, 2012, 01:48:16 AM »

Pretty motor installation.

Dennis Adamisin · « **Reply #18 on:** February 08, 2012, 11:34:14 PM »

Quote from: Jeff Traxler on February 05, 2012, 11:59:05 PM

Hey Bob,The plan is to be there this year.I look forward to all the escapades that week will bring in the campground I'm sure I'll talk to you before then.

Dennis,That is the red El Cheapo motor I showed you at the Signal Seekers contest.It nosed over on a earlier flight and kicked up a little dirt before shedding the prop.My helper hit the panic button pretty quickly and no damage happened.I blew out the motor and put on a new prop and it has'nt phased it at all.I want to try one of the new wide blade props with a little clipped off the tips.I'm in for a half dozen when they are available.
Jeff

Got plenty of 12x6.5 Wides left @ $6 each plus shipping. PM with you address & I'll get some in the mail to ya!

Jeff Traxler · « **Reply #19 on:** July 03, 2012, 12:19:49 PM »

The Latest.......I have well over a hundred flights on this ship and It has performed above and beyond my flying capabilities but has helped me progress as an intermediate level flier.The fuselage construction is a keeper but I will modify the front where the battery goes with construction similar to Mr. Adamisin's new design ideas.My CHAS has performed well and just recently I tried the new KR-2 timer.I like the simplicity and ease of programming of this timer and the ability to use the less expensive ESC's.Eric Rule from RSM took good care of me and got it to me FAST.All in all this has been a wonderful learning experience and I can't wait to apply what I have learned so far.Jeff

Dennis Adamisin · « **Reply #20 on:** July 03, 2012, 02:09:53 PM »

Well over 100 flights is Trax Tested Tuff. Dependable e-power is great but having a robust airframe makes all the difference in the world. Your new fuse construction will take it all to a new higher level.

ONWARD Trax!

Jeff Traxler · « **Reply #21 on:** July 03, 2012, 02:34:19 PM »

Thanx Dennis
Onward it is

I plan to use the new nose of your ship in the 2 E-Banhseeks I am working on an I plan to make an identicle IC version to let people fly and then fly the E version for comparison.It will be nice to see how this construction holds up with the vibrations from a "Rice Burner" but I think it will be OK.At any rate it will be Trax Tested Tough

Bill Little · « **Reply #22 on:** July 03, 2012, 08:19:45 PM »

Very nice work, Jeff! And the new techniques are what's great about the hobby. And the fact that it can be shared in seconds with others through the internet!

Keep on keepin' on!

BIG Bear
RNMM/AMM

Steve Hines · « **Reply #23 on:** July 03, 2012, 10:04:42 PM »

Jeff it could be the plane, but I think you are really flying well this year. The Ruffy looked just as good at brodak as the Pathfinder.

Steve

P.S. little bagger says Hi!