Vlog #15

I returned to the hangar for a week and did more wiring behind the panel and engine. The loom for all the engine senders is now prepared and ready to install into the airframe. One of the biggest delays is waiting for a shipment of parts from the US, which I have just released.

I will be back up next week for four days with a bag full of parts to be installed. Vlog 15 is now up.

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Vlog #14

Vlog 14 is now covering the terminal strips, securing the spade connectors and setting the pressure switch for the fuel pumps.

It was a frustrating time as now the aircraft is just a huge logistical issue with parts to complete the tasks being the central issue or the lack of, combined with long deliveries. Several tasks still need to be finished for this reason, and I am trying to have complete systems at this time, so it is frustrating.

Leaving for a holiday but back to the electric string on my return

https://rumble.com/v257nsw-tucano-r-at-rylstone-vlog-14.html

Christmas 2022

 

Well, here we are another Year and still on the work site. While I can be frustrated with the last 18 months, I have to thank God I am still alive to work and enjoy life and family. While this has been a lost time, it has made me put things in order and appreciate what I have, family, friends and sunny days when they are there.

I have been thrust back into doing the wiring and am inching forward. Some circuits are tested and working, while many I have tested to complete or gain the courage to apply the voltage. The Vlogs will be coming next year with useful tips and, if not, something to chuckle over.

This aircraft has been a learning experience and one of the most intense in my life. While showing some of my strengths, it has exposed many weaknesses for me to overcome.

The wiring has reached the point where the runs have to be organized, and that is as welcoming a thought as tidying up a pit of black mating vipers, but someone has to thrust his hand into that pit.

God Bless, Merry Christmas and a Happy New Year

I took a few photos just before I left. 

Pity me.

Paper Work, never-ending but it helps

Vlog #13

This is a general overview of the wiring status at this stage, with details on preparing the wiring for the throttle handle with a propeller and frequency flip for the radio available.

Vlog #12

 This Vlog covers the installation and user-adjustable flasher supplied by Custom LED to allow up to 10 selectable flash patterns.

The bracket was printed using ABS-PET plastic, filled and then sanded with 100 then 400 grit aluminium open-cut paper to achieve a smooth finish; then, 3 coats of acrylic polar White were applied to achieve a reasonable finish.

The unit is secured using M3/M4 S/S screws fitted to brass inserts installed into the plastic mounting block. 

Comment:  All the brass inserts had to be chased out using an appropriate tap to ensure smooth assembly.

When assembled finally, star washers are installed under the needs of the screws as required to secure them in place.

A pair of relays had to be used to simulate the off-on-on operation of an AN3021-13 switch that proved impossible to source, adding to the complexity but I was willing to keep my design parameters.

All in all, works well.

Vlog #11

The second of the wiring vlogs is up and covers some of the tools and techniques used up to this point. For those following the Blog, much of this is covered under the wiring tab.

Line to Blog - Click Here

Link: https://rumble.com/v1nxqv0-tucano-r-vlog-11.html

Vlog #10

 Vlog #10 is now up

https://rumble.com/v1my7jg-tucano-r-vlog-10.html

This will be the first in a series of maybe how not to, but it will be what it will be.

Vlog #9

 Vlog #9 is up on Rumble

 

Engine Induction Update

This is a short update to show where the induction is and our hope.

As you are aware, I have, in conjunction with Joe Newham, developed a new manifold to use a TBI from Rotec. This has been a side job with trying to assemble a complex aircraft, but it is approaching the pointy end of the exercise.

A manifold has been successfully printed in Ultem 9085 and is assembled to do a trial on an engine stand, see Vlog #8.

The manifold is identical to the one below, which is ABS as the 9085 is 50 cents a gram

We are as sure as one can be that this should work as the TBI now shares the same design feature with another aftermarket induction system that makes it possible, and we know that one works under boost. This will be determined soon as the engine has to go one way or another.

If it works, it will be cool......................!

Vlog #8

Repost I messed up the link

New Vlog #8 on the Tucano. This vlog covers mostly the fuel system and its features, along with and at the end, a short vid on the wing installation and undercarriage. 

It does look cool in the Battle of Britain camouflage scheme.

https://rumble.com/v1g1dl9-tucano-r-at-rylstone.html

or

click image

Vlog #7

Vlog #7 is now up on Rumble - Click on imiage.

Link: https://rumble.com/v142olc-tucano-r-vlog-7.html?mref=15uxh&mc=1nrd1

Vlog #6

In this Vlog I cover the issues of removal of the tanks on this Tucano and the scheme that I used to achieve this, part 2 will come later just before the wing installation.

Have fun

Vlog #5

Vlog #5 is now up on Rumble

 

Vlog#4

It was a week of consolidation and detailed work around the engine but at this time all the rigid and flexible lines are finished except the fuel lines too and from the pump but that is for a later time.

Click the image for the link

The paint clearing will be done rain or no rain as I have the sign-writer booked for the 13th of April. Once done the planning for wing installation will be a higher priority. At this point moving into systems and away from construction.

Josh the Avionics man will be over for a week to finish checking the electrics and in particular the engine instruments trying to have that happen before the wings are fixed on

Vlogs on Tucano

Its been a long time between posts and there are a number of reasons but the lockdown and some health issues ate all of 2021 with little progress as I was unable to be at Rylstone. When I left I had three [3] big bits in two wings and a fuselage.

The aircraft has reached a phase where the dedicated posts are not possible, they will occur as the various task is complete and there is a story to tell. So here are my humble efforts all shaky-cam with poor voice over.

These will only be posted on Rumble as I disagree with the competition.

Any questions or comments I am here.

Have fun  and click on the photos below for a link

Comment

None

Exhaust Installation

This blog covers the muffler installation after repair.

Overview
In a previous blog, the issues with the selected exhaust system were covered in detail. What I was not prepared for was the total lack of support from Akrapovic.

After the initial contact, their Australian agent forwarded my simple request for the material type to the factory. As it was manufactured from titanium, my welder wanted to know the material to allow the most suitable filler rod to be used - simple, eh! - no!

My request was greeted with a weasel-worded corporate reply or "We don't want to know."

"Project for Rotax 912 has been concluded directly with the producer. And therefore the nature of the project as well all related conditions of the product, as well as agreements with a partner, are strictly confidential, and we are not allowed to share any info. And since the product is used in particular conditions, my high recommendation would be to contact the seller of your product directly and place the question to them directly.

I apologise that we cannot give you the information you need.

I thank you for your understanding of the situation."

Milan Hernaus

Aftermarket Country Manager 

Repair

The builder decided that the most likely material was Grade 2 Titanium due to the amount of fabrication with a Grade 2 filler rod was purchased. Peter Goard welded the muffler after modifying the internal pipes to the specification outlined in a previous blog.

Poor support..!

Installation

The modified exhaust system was fitted to the engine fresh from a Marwen zero time rebuild and installed onto the engine.

As seen in the attached photo, it meets my specification allowing the radiator and oil cooler to be installed as planned.

For detail of the installation follow the link to my Vlog

https://rumble.com/vw44ju-tucano-r-at-rylstone-vlog-.html

Comment

If it all goes well in service, I will then be happy.

         

Painting

Comment

Painted, at last, Painted at last.........!! 

When he awakes, tell him there are a few items 

to be still to be painted ..!!

Painting Markings

This blog covers the aircraft's war paint

Overview

Camouflage Details

One of the first issues encountered was identifying the colours used on the markings and regardless of how much searching no commercial standard could be identified, unlike the main colours. After discussing this with the paint supplier it was decided to use the BS381C standard and find colours that were as close as practical. With that decided an order was placed for the six [6] different colours that had to be used.

Dark Earth - BS381 350 plus 22.5 K73 per liter {match to Vaellio Model Paints]

Forest Green - BS381 241

Duck Egg Green [Eu de Nil] BS381 216

Underside - Duck Egg Green BS381C

Roundel Blue - Roundel Blue BS381C 110

White - Pure White W351

Bold Red - BS381C 564

Canary Yellow - BS381C 309

Lt Aircraft Grey - BS381 627

Black - Satin Black K73

An issue that had to be resolved was the orange peel from applying 2K clear to the port wing. After completing this task it was decided that a coat of base should be re-applied but it crinkled everywhere it contacted any clear that remained, a quick read showed that this is a no-no. 

The problem had to be resolved by stripping back the wing but it was now clear that all base colour would have to be applied before attempting to apply the 2K clear.

As an attempt to control weight it has been decided to use vinyl film and spray paint for the roundels and tri-colour. A low tack vinyl was selected and were cut after producing the necessary graphics using the sketch above to obtain the correct proportions allowing all these profiles to be masked up in one operation.

After the airframe and wings were in undercoated, the vinyl is applied after the relevant colours applied by removing the relevant mask, finally when each colour was dry each mask was reapplied to complete that marking. 

Applying these decals is a skill but the use of clean water with a solid squirt of washing detergent is a must. They were floated into position and massaged into their correct location. 

Disposable towels are used to remove excess water with particular attentions paid to edges to ensure they are as tight as possible. The large decals we all cut into manageable segments for this task as they cannot be handled as a single unit.

Generally, I started with the dominant colour blue, next a white after applying a light coat of primer, then finally the red. The side was the same except started with the yellow and primer as required. Finally the tail tri-colour was just applied in order as seen in the photos

With the first mask reapplied a rattle pack off primer, high build used to lightly cover [tone down]  then the area for red was  applied and once dry the mask applied.

Particular attention was paid to the gaps that created by segmenting the decal, it is impossible to create a perfect profile match as they distort on application especially over rivets.

At this point, the Earth was applied, then Forest Green with the pattern marked out at the start using the diagrams above. All the outlines were marked using the Earth and the gun on its tightest pattern.

Comment

It is just one big learning curve

Painting Wings

Preparation

With the wings off to fit the tanks and tidy up all those small details and the decision was made to paint the underside of both in Duck Egg Green. The first task was to remove the fibreglass tops and mask up the wheel well, tips and other items requiring protection.

The wing was moved under a 6 x 3-meter gazebo, with the sides closed the wing, next, a thorough check as made and all those overclocked tasks were resolved and finally, the whole service was cleaned using water/detergent and 3M Ultra Fine sanding Pads and dried with paper towels. Both undersides were wiped using lint-free towels with wax and grease remover and wiped with the same then finally with a tack cloth.

Four [4] small blowers were mounted onto a work table to help extract fumes and overspray, it was decided to use smaller blowers as if a large set of fans were used it would mean lots of air coming in creating the need for filters.

An Apolo 5 stage turbine sprayer was selected for a number of reasons,

The first one being as I am 100% dependent on solar and thus have limited power for a large compressor. Another reason was they produce very little overspray due to the low pressures used and they warm the air helping to dry it for spraying. A  full-face mask was purchased to spray all the 2K products along with a mask/filter for the undercoats and base.

Personal Up Skilling

The internet is a good source of information but it has to be filtered, listed below were two key pieces of information that helped me make a decision to pull the trigger. Many hours were spent looking and absorbing as much information but end the end its spraying that is the final judge of all the effort.

2k paints are thinner than water, the first coat is a 'dust coat' - it means just that, dust the paint on, do not attempt to cover the whole surface with paint with the gun. Since the paint is so thin, it will spread and evenly cover the surface. For the second coat, lay it on a tiny bit thicker. It is difficult to see how thick you're putting it on though. You'll find after the dust coat has had a few minutes to settle on the panel, it will form a solid colour and the dust effect will go away. This will now give you more surface area to cover with the second coat, hence needing more paint.

[The comment above was extracted from a painting forum and proved to be of great value]

Jake LeStrada "No Fool Zone"  was a personal mine of information on using an HVLP and was the final link to give me the courage to pull the trigger.

Painting

Concept Paints 103 etch primer was thinned 1:1 using approved thinners, strained into the paint pot and after test applications on paper was ready to apply to the wing. A light coat was applied. Next,, the whole area was scuffed with a 3M Ultra Fine Sanding Pads using water with detergent, this didn't remove the paint from the rivets like 600 grit would have thought it was used in some areas. Once done the final feel was smooth so the next step was to proceed with applying base colour.

No high build primer was applied to save weight - my gamble.

Once ready the Duck Egg Green basecoat was mixed 1: 1 using thinners supplied, strained into the paint pot and after test applications onto paper the first coat was applied. Though it looked OK there was a lot of orange peel and this was traced to operator error, to fix this, it was sanded over an afternoon.

With the next application, the thinners were increased slightly and the fan width narrowed from wide open. The gun was held at an angle of about 30 - 35 degrees to the wing surface with the rear fan nearly parallel tracking the spray line and the top side blending the previous pass. resulting in a smooth glossy even finish.

Note: Doing it again I would spray lengthwise on the wing to reduce overspray

This is an entirely different task as the paint required a catalyst and is mixed in a 2:1 ratio and it is potentially dangerous. For all paint 2K operations, the builder wore a full mask with external air supply supplied by a separate compressor, this is only required for the 2K.

At locations, where covers are to be installed are masked before painting to create a clear indicator to anyone that something is missing when final assembly is complete.

Finally, 2k Satin Clear was prepared in the same way and two light coats applied.

Comment
Painting, at last, painting at last.........!! 

The front leading edge of this aircraft was riveted using countersunk pop rivets as discussed with the factory in the early days, since that time the factory has gone all dome for a number of reasons but mainly from the experience gained from multiple airframes. My efforts we a mixed success with the primary issue being dimpling in place with a hand tool, doing this again I would have dome riveted along the rib line and countersunk rivets along the stringers to remove the visual intensity that creates.

The next task will be to have the signwriter to detail the underside of the wing to reinforce that military-style theme of the project along with the roundels and will be covered in a separate blog.