Did my Spektrum PowerSafe receiver just save my airplane?

Had a nice day flying at our Annual Toys for Tot’s charity fundraiser yesterday and today did the recharge on the flight packs on the plane I flew.  This particular plane has a pair of A123 2300mah batteries that plug directly into my Spektrum PowerSafe 9110 receiver.  This thing is a $200 item but it’s main feature is the ability to plug two batteries directly into the receiver via high current EC3 type connectors.  With this method the power supplied to the servos is shared between the packs and does not have to go through any switches.  A soft switch is used, which means if the switch fails the airplane is on and the current to run the servos does not pass through the switch so it is not a limiting factor in supplying power to the high torque digitals that are used on all flight surfaces of this aircraft.

When I went to recharge the batteries I started with the port side pack (just because) and charged them up to full… they took about 850mah.  That seemed high as I flew maybe 3 or 4 times and none were much over 7-8 minutes.  As I moved to the starboard pack something even more interesting occurred.  The charger said no battery was present!!  Double checking the leads quickly lead to the discovery that the negative lead ended in a nice solder ball that was no longer attached to the battery!  At some point it had become disconnected…  I don’t know if it was vibration, poor solder joints (from the manufacturer…  I didn’t have a hand in this connection) or some combination of the two.

I have no way to know if this happened before the flight or during but I can tell by the fact that the second battery took only 100mah or so to charge that I made several flights without it!  If the connection was dead before I took off the first time… then it really would have only meant I wouldn’t have flown that plane on that day if I hadn’t had this system.  If it broke at some point during the first flight it likely means my airplane is only here today due to having the redundancy in the system.  Glad I had this system.

Of course, this receiver is not the only way to get this level of redundancy and reliability.  There are other power distribution systems out there but for this size and type of airplane I think its a very nice option and one I will probably continue to deploy.  I will have to look at my pre-flight and assembly routine to see if there is a way I can check for this failure mode in the future.  In the meantime its nice to know its there protecting me and my airplane from disasters.

Updated throttle servo linkage on the P51

Spent a few minutes last night to make a few changes to the throttle linkage that caused me issues on the P51.  Here is the updated version.

photo3

As you see I swapped arms to a fixed heavy duty Hitec arm as well as shortening the 2-56 rod and soldering on a coupler that takes me to a 2-56 threaded end.  Then put a clevis with jam nut and retaining clip on to minimize chances of another disconnect.  After getting the jam nut tight I coated it with a bit of clear finger nail polish to further eliminate any vibration induced loosening.  I then coated the threads on the screw going into the servo (which are all metal) to help on that side as well.  I could use some thread lock but need to make sure I can move it one more time when I adjust the throttle throws (if necessary) whenever I run it next.

I am open to suggestions but I think this will eliminate a re-occurrence of the issue that has me ordering a new wing!  At least I hope so.  The throttle end is held on with a 4-40 bolt through type ball link connector with a nylon insert nut so I don’t expect issues on that end.  I cleaned up any other issues under the cowl and will reassemble that tonight and then the Mustang will get parked safely in a corner of the shop until the wing gets rebuilt.  Probably will become a hangar queen for the winter and look forward to maiden day next year!

 

P51 crash landing… investigation Part 2… Conclusion

Continued the investigation tonight.  Set the body in my trusty PVC holders on workbench #1 and started examining from the front.  Pulled the cowl and found a couple minor issues… One cowl screw insert coming loose, ignition box moving a bit, but no smoking gun under the cowl.  Even pulled the plug and examined.  It actually looks like I have heard it should.  Sort of uniform dark grey.  Gap looks fine and no carbon buildup obvious.  Top of the piston still nice and shiny as well.  All linkage and tubing plus the telemetry sensors and wiring looked OK.  I then decided to skip an actual ignition spark test for the moment and moved on back into the wing saddle area.  Again nothing obvious so I turned on the plane and started looking to see if (as I thought) the ignition voltage sensing is beyond the kill.  The plane died quickly like that occurred but the telemetry didn’t show the ignition voltage loss.  This all worked as expected but it brought to mind the idea that maybe I had a throttle curve that brought the throttle below idle or some sort of misconfiguration of a mix that would cause that.  Looking at the radio yielded nothing but when I moved the throttle back and forth I saw some odd movement and looking more closely I found the culprit.  Here is the problem:

photo With this screw backed out this far the adjustable arm can end up extending enough to cause the throttle to bottom out and shut down the engine.  As you can guess, I will be coming up with a different type of connection.  I know, some folks will say this type of connection in a big gasser is just stupid to start with, but with so little force required to move the throttle I was not worried about torque causing slippage or the arm bending or any of that.  What I obviously should have been concerned about was vibration loosening the screw!  I will probably replace this linkage with a standard threaded clevis (once I solder on a threaded coupler) and a standard servo arm… non-adjustable this time…  A drop of something to keep the screw in place might be used as well.  Perhaps nail polish or the like.  I don’t think thread lock works on nylon!

Obviously its hard to be happy about a crash but the good news is the damage seems to be limited to my pride and the wing.  My pride will recover… its a nasty bruise but they heal.  The wing is not that difficult to replace, and not very expensive in the grand scheme of things.  The better news is that I now know what caused the crash and it is easily rectified.  I was hating the thought of fixing all the damage and not being able to figure out a cause.  That would really make me paranoid and give me no confidence to fly the plane again.  Now I’m back to looking forward to it!

 

P51 crash landing… investigation part 1

Pulled the landing gear and servos out of the wing this evening.  Port side gear bay and main spar and ribs took the brunt of the damage.  Cracks and buckling apparent.  Would be difficult to fix.  Would need to re-manufacture at least one rib and remove and re-web the main spar.  I imagine parts of it are cracked or broken as well.  The other side the top sheeting and some of one rib is crushed.  I am fairly sure I will just order a new wing this fall and reconstruct over the winter.

Both retracts had some flexing/bending of the mounting ears.  The starboard side was bent worse as you can see here.

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Some hammering against the anvil/vise seems to have straightened those out pretty well.  I don’t expect the retracts are actually hurt at all.  They seem to operate smoothly and the struts compress as before.  Best I can tell everything is pretty straight again now.

I need to carefully inspect the fuselage but on first inspection it looks unhurt.

First look through the telemetry data has nothing significant to help pin down a cause.  Both the pack voltage and ignition voltage stayed in range both before and after the engine quit.  Overlaying the altitude and RPM graphs it is pretty easy to see when the engine plummeted in RPMs over a few seconds, ending at zero!  I will have to carefully examine the wiring beyond the sensor, check the ignition itself as well as the plug, the hall sensor and of course the fuel system to see if I can determine a cause.  The log showed no signs of problems and even if it had gone to failsafe the throttle would have simply gone to idle.  I will confirm that too but don’t believe it would have quit if I took a hit and it doesn’t appear I did anyway.  There was plenty of fuel in the tank when it quit so will be sure to check the plumbing as well.  Still a mystery for today.

P-51 crash landing today

Due to a flame out at a very bad time the P51 made a landing in the bean field 20 feet off the end of the runway.  Analysis is underway to try to determine a cause and assess damages.  Quick guess is the wing will need to be replaced due to landing gear attachment point damage.  More to follow when I have time to work on it. Will be looking at telemetry data as well for info leading to reasons behind the failure.

Flyzone Beaver – update 3

Flew the Beaver last weekend at a friends pond. Even with gusting winds to about 13 mph the new water rudder rigging worked well.  With that issue fixed I would say it taxis and lifts off the water well.  The only possible draw back I can see is that when the float with rudder lifts first it can cause some minor directional changes while the other stays down.  This is brief though and doesn’t represent a real problem. The new linkage is definitely a major upgrade from the ridiculous design that Flyzone utilized out of the box.  I’m not saying this one change makes this plane a winner but it at least resolves one of the biggest drawbacks that directly affect its performance as an airplane.  Now that taxiing and flying off water are more easily accomplished.

If you have or are considering purchasing this plane I highly recommend you do something similar before you even attempt float based operations.

One other positive to report is that after an unfortunate wind gust the airplane ended up floating upside down.  After minutes of this a recovery was made and the plane was found to have taken on so little water that no problems resulted and the plane was immediately ready for another flight.  This is often not the case with other float planes but the Beaver is light and buoyant enough to survive a dunking without taking on much water.

This experience has raised my opinion of the Beaver slightly but I don’t expect to be writing any fan letters on the product anytime soon!

 

More P5-1 flights and Skydiver has problems…

Three more flights today on the P-51 today.  I think they were number 10-12 on this bird.  She flies well with adequate power from the DA-50 and with full flaps the landings are getting to be smoother all the time.  No appreciable bounces today and 2 landings that were totally greased in.  I may have to start saving to modify the retracts to electric power and consider installing them if I keep this up!  The Top Flite is a really nice flying model.  Once you get the flaps dialed in with a little up elevator mix on deployment it isn’t too bad to land.

On the skydiver front, George had a bad day.  After a successful early jump, the next two were ugly.  First, the release mechanism didn’t and he stayed firmly attached and then on the next attempt he did a “hanger” and simply drug along behind all tangled up and just to add injury to insult his arm busted off when I landed… 🙁

He has already been repaired and is ready for the next attempt.  Also had a scare with misplacing his “static line” that attaches to the plane and allows his parachute to open upon his exiting the airplane.  I eventually found it but it has inspired me to build a second one as a spare.  If I can find a little cheap metal spring hook I think I will be in business.  The rest is easy… just a release pin in the middle and small patch of hook and loop on the end and I’m in business.

 

Three more P51 Redtail flights today

Put up 3 more flights today… about 7 minutes each.  Total battery usage was around 480mah so the average looks like ~25mah per minute of flight.  Even less than last time but probably less “on-time” between flights etc… so more typical of actual flight times.

Finally got my flap mix to elevator about right I think and all three landings were good.  1  bounce or less and no really anxious moments.  Just greased’em in!  One flight I got a reported 96mph so I think maybe 100 is going to be the top speed if I get in a nice long full throttle dive unless I make some changes.  I can’t complain about that.  It seems reasonable enough.  I’m not seeing any excessive temps… around 230 I think is about normal peak which seems on the cool side so I’m not going to complain.  Flight pack voltage is very steady with the two A123 packs supplying a nice and fairly steady 6.5 or so volts if I recall correctly and the IBEC is locked in at 5.2V.

Did some nice, slightly high, photo pass/knife edge passes and some sub 30 foot high speed passes along with a few Immelmans, Split-S, loops and plenty of rolls and combinations.  Stall turns are fairly easy and I am having few problems with orientation.  All in all, its shaping up nicely.

After the 3rd flight I sat and made a few adjustments in the radio.  As is my usual method, I started with dual or triple rates configured for each of the main flight surfaces and once I narrow down throws and expo settings I like the rates go away and all are set to the same settings so there is no chance of problems due to improper switch settings.  Ailerons are pretty much dialed in and rudder is comfortable though I may need to fine tune a bit.  Elevator is nice for landing but the plane can snap if I pull too hard.

I’ll have to decide if a bit less elevator is still good enough for landing but other than that I’m getting pretty comfortable with the Red Tail.

Jumping Jack RC Skydiver made 6 jumps today!

I have a “Jumping Jack” Skydiver (static line… i.e. chute opens on leaving the drop “box”) that we dropped 6 times today.  Only once did we have a hangup where some of the rigging got caught and he stayed hanging under the plane trailing the chute and not letting go.  All other jumps were successful.  This is especially gratifying since this was the first time that we had dropped him with the addition of an American flag trailing about 6″ below his feet.  The flag is 8×12″ and it looks pretty good trailing below him.

Here is a shot of Jumping Jack (I refer to him as George ’cause my father was 11th Airborne and his name was George).  As you can see he has a safety orange para foil type of of steerable chute.

JJackwithChute

As you can see below; in the front of his jumpsuit is a battery (I normally use a 2S 6.6V 200mah LiFe from Hobbico) and an air alert to help find him should he find his way into the adjacent farm field.  The receiver is hidden in his lower back area and he has Servos at the shoulder of each arm that rotate his arms up and down.

JJackAirAlert

Here’s a shot showing the flag I have just rigged up to trail along below George.  It actually works pretty well.  In fact I think it acts as sort of a rudder so if you just don’t touch any controls he tends to steer into the wind!  As you can see I used a couple pieces of soda straw to allow the flag to rotate around the rope without causing anything to tangle.

 

JJackFlag

The two lead sinkers (split shot) at the bottom keep the string more or less vertical and the top one keeps it from riding up on the string.  The flag is hot glued to the straws.  I used two so I can fold the flag over double top to bottom and then I fold it in fourths so it will fit up under the plane trapped between George and the plane until release.

 

JJackRadio

Here is my specially setup radio for steering George around.  The left stick controls his left arm and the right his right arm.  Left arm is “Aileron” and Right is “Rudder” for those of who fly mode II.  If you push the right stick to the right he pulls down on the rigging and turns right.  Similarly if you push left on the left stick he will turn left.  If you push both simultaneously he will slow his forward motion.  Pulling the sticks toward you does nothing.  Fully pushing away from center on both sticks causes a “flare” which slows both his forward and downward motion.  Highly recommended just as George touches down to keep George from breaking his legs!!

Every successful release today resulted in a touchdown within 20′ (at worst) from where we were standing.  George is quite easy to steer and he can pretty much hang in a 10 mph wind while losing only a little horizontal ground.  On the 6th jump his battery died and he turned into the wind, I suspect largely due to the trailing flag, and floated down nicely.  Thanks to a good drop location choice… slightly upwind and high… he was just off the field and easily retrieved.

Thanks to Kelly, my Jump pilot, the Telemaster that carries George up came back safe from every flight as well even when we ran it empty!

 

P51 Redtail History – In honor of my buddy Tim

My Red tail P-51 Mustang started out life in late 2004 as a standard Top Flite Giant Scale P51 D purchased by Mr. Tim Mills.  Tim bought pretty much everything needed to get this bird flying during a 1 week period.  Everything from engine to scale exhaust, servos and retracts, as well as the ARF itself and more.  When it arrived he started to convert it to a B model by stripping the body and adding the turtle deck aft of the cockpit using a Top Flite conversion kit.  The structure got finished and the body glassed and prepped for painting.  Tim wanted his P51 to “represent” the Tuskegee airman as he was one of the few black men involved in the RC flying hobby… at least in the greater Indianapolis area.  Tim had done some reading on the subject and found that the Tuskegee had first been issued B model mustangs so he had to convert his.

For some reason, at that point the project stalled.  I don’t know exactly why it stalled.  Likely Tim got involved helping out friends who needed some assistance with anything from Airplane setup to health issues.  Tim was the guy everyone called when they needed a ride somewhere, a helping hand with a home project, advice on flying and setting up RC planes and just about anything and everything else.  Tim had built and driven drag bikes as well as running a race circuit earlier in life, been an owner/driver of a semi-truck and maintained and rented out properties.  He was a Jack-of-all-trades and always generous with his time.  He was also a big talker and loved just hanging out with the guys at the flying field.  He helped me learn the basics of IMAC style flying and we traveled to a few events together in the last 4 or 5 years of his life.  With Tim in attendance, it was always a good time for me.  He also spent a good amount of time working on RC projects with me, both his and mine, out in my work shop.  I learned a lot during those sessions and like to think I taught him one or two things as well.

In any case, somehow the Mustang languished for almost 7 years and everyone had a good time asking Tim when the Red tail was going to be ready to fly.  This continued until Tim passed away in February, 2011.  I had personally benefited from flying and traveling and just becoming friends with Tim and I wanted to finish the Mustang in a way that Tim would have enjoyed so I contacted his nephew and bought as many of the parts Tim had acquired for the Red tail as I could.  I hadn’t planned on this project but I scraped up as much as I could and bought the Airplane, motor and Keleo scale exhaust at a very reasonable price.

By spring of 2012 I had the plane ready to fly and besides adding the distinctive red tail and other markings unique to the Tuskegee airmen, I added a few special touches toward making it a bit more of a memorial to Tim.  These include a pilot figure (black of course) who is clothed in appropriate attire and can salute on command from the transmitter; graphics on the cowl proclaiming the airplane name to be “Drag Racer II”; and adding the pilot name to the side of the cockpit area.  The call sign “Smooth” was chosen because not only did Tim enjoy Jazz music but many folks described his flying style with that word.  Here’s a picture of the cockpit area.

IMG_1732

There are a few other nice touches I’ve added to the bird to make it unique but I’ll save those for some future posts.  I’m still working on learning to fly this plane sufficiently well to be comfortable and trying to keep it looking good in the process.  I’d hate to lose it in an accident and that is the reason it hasn’t flown much yet.  Recently though I’ve decided I just can’t let it become a hangar queen as I can easily imagine Tim’s reaction to that.  I can hear his voice in my head right now saying “Just fly it, man!”.

As I do just that, I’ll post some more information and pictures on the Red tail.  I hope Tim would approve.