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PostPosted: Tue Jan 30, 2007 9:20 pm
by xgary
Russell ,

The tapered rod is one thing then you have to bend it around it .

PostPosted: Tue Jan 30, 2007 9:53 pm
by xgary

I am not an engineer by any means but ther really is nothign wrong with the nose ribs. They just keep the D cell -D shaped and hence strength is kept.

You can make all the nose ribs in 15 mins
cut your sheet into rectangles
sandwich them all together with a template on each end and run the hot wire over them.
or a bandsaw --what ever you prefer.

why not just get a few new d cells < snickeR

PostPosted: Tue Jan 30, 2007 9:59 pm
by xgary
You guys gonna be begging for these dcells soon.

I am doing a 2 seater rgiht now and I think they re about the same as teh Elite wing. So I am planning to make all wings the same with the extra stiffners.

You should be able to hang a rotax 503 on each wing now LOL
>> JOKING < 104 HP would be a riot -- too bad they weigh 110 lbs ready to go with gear box


PostPosted: Tue Jan 30, 2007 11:44 pm
by flyalaz
Hey Shorty,

I would if I could, but I can't so I won't! Hee hee! As much as I would like to, it just won't fit in my budget.

Hot wire foam is the easiest and cheapest method by far, but I have to fire that pipe up once in a while or the grey matter stagnates. I just liked the idea that metal riblets would never come loose, or have the glue bond pop off and have bits of fod rattling around in there.

I'm just glad that you decided to go ahead and do this for all to benefit.


PostPosted: Wed Jan 31, 2007 6:55 am
by xgary
to be honest the glue does become hard over time but that does not mean the ribs just simply fall out.
Her isa pic of a 2 seater wing i just opened up . Ribs were only loose where hte damage was but the rest wer intact and did not fall out of u channel

Proper fitting is the the key and when the ribs are glued in and all damn near true to each other , then you set it into the new leading edge and lightly press it into place. I have a jig in my shop that does this and the spar is clamped into the leading edge skin and the foam ribs are held tightly to the skin. Once it all straight and true then you rivet it .

Material cost for the complete Dcell is the smaller part of the construction.
Rivet cost plus 2024 then add in all the time to get materials.
marking it
cut it
bend it
form it
glue it
assemble it .
Huge time !!

but very impressive product when done.

PostPosted: Wed Jan 31, 2007 7:02 am
by uscgairdale
Man, what an opportunity for people to get some really nice wings for themsleves. I'm tempted to get some d-cells just for the sake of having them. Lets see, Shortys making the d-cells, and if Tyler makes the EC pods available, and George makes all the fuse components.....that makes a brand new Lazair!

It sure is nice to have people putting forth the effort to keep these machine in the air,


PostPosted: Wed Jan 31, 2007 9:44 am
by xgary
I should buy that ser 3 in London to make a mold off the original pod that comes with it .

but if some has has touble buying as d cell for 1500 then a pod for 1 k might be outta the picture as well.

Also , I am thinking of make one wing -- all the 2 seater specs +

Only thing you will need to add is a u channel to bottom of each rib and a "L " bracket to spar. I have another trick for the root box as well that shoud increase that weak link by 20 to 30 % .......

PostPosted: Wed Jan 31, 2007 10:46 am
by JPXman
the glassman, mike mckusick will build a carbon fibre factory pod for $750 US. i have been poking around for interest in that but there is none, i'd love to get an order for 3 or 4 pods and get them done so he can work on them and have a great product. with my newfound knowledge of the EC I could make all the required hardware - its really not as bad as some people say. the pod part that moves is only held on by two bolts! its all the fittings that make the pod move that are numerous yet simple L-brackets mostly.

shorty, are you going to put in a kick spar to support the sparbox? and is that a pic of gerry's 2-seater? i heard he had a run-in with a bean field.

Shorty, people might be skeptical about your Dcells purely from your apparent abrasive nature, however maybe if you posted some detailed info about construction and a few pics of your jigs people might get on board. Also, I think if you sold a complete kit *including* covering materials that people would jump twice - having a new wing with no covering is kind of useless..... buy a roll of tedlar buddy and sell the complete package.


PostPosted: Wed Jan 31, 2007 1:46 pm
by xgary

Mike McKusic 750 us == 1k cdn ? or close
shiiping will kill you and courie even more at border.

D cells will be kick ass...... all will be made same as 2 seater pusa few more mods. Wing jig is 27 years old now .

I have seen other repairs done on dcells , i have another set of ser 3 that came in this week and are BEAT TO HELL . there was no explantion other than someone else did it . LOL

I won't be too abrasive -- i do use a file . <snicker>

Pics will come with specs soon with finshed product adn a few shots in between.

I tell you if you dont have a wing jig -- it would be near impossible to insert spar/ribs correctly.