Hangar 9 Carbon Cub 15cc ARF … Part 3

In part 2 of my commentary and running monologue on the Hangar 9 Carbon Cub, I mentioned that I would cover the bottom vent that I added and some other mods so I will show you a couple of those here as well as try to relate my sense of how she flies. First the build and modifications update.

Bottom Vent

Looking at the cub I realized there is not a lot of accommodation for air flow and even if it isn’t much I’d like to have at least a modicum of air passing over my batteries inside the cockpit area. So without just cutting open a whole section between formers/bulkheads in the bottom of the tail I needed another solution. What I came up with was to cut open a section in the only solid area behind the cockpit, which is the hatch for servo access. I happened to have some louvers laying around that I picked up at a swap meet so I cut an appropriate sized hole and drilled a few holes for button head #2 screws and created a nice louvered exhaust vent. It’s very nice looking (even if not quite scale!) and looks like it belongs there. Was it enough exit area… well read on.

Top Hatch blows off!

Taxiing out for the first flight on the airplane, everything seemed great. I had done a balance check, the prop seemed to be well balanced, producing a minimum of vibration, all the surfaces were moving in the proper direction and with the proper authority… Nothing left to do but fly. Unfortunately upon reaching about half throttle, about 10 feet into the takeoff roll the top hatch that I had created decided to eject. Testing a second time showed the same issue. It hadn’t been jolted loose on a bump either it was simply being swept up by some combination of the air moving over the top of the wing and the air pressure forming inside the plane as the motor forced air into the various openings in the firewall. While the louvers I had installed on the bottom of the plane might insure a good vacuum to pull some air past the batteries once she was in flight, they didn’t do enough while the plane was just starting to roll to avoid the top hatch getting popped open. For the day, I simply applied some box tape along the front and rear edge of the hatch and things were fine from that point on. For future flights I had to do something to make the latch mechanism a bit stronger. Clearly the magnets I had in place were insufficient.

Before the next flight I eliminated the magnet and screw head that I had used to secure the hatch and cut a groove in the wood and created a tab using a servo horn to form a rotating latch that would insure the hatch stayed in place. Ten or so flights later, this seems to work well.

Servo arm loose on rudder!

The final lesson re-learned on the second or third flight of maiden day for the Carbon Cub was that you should always tighten all the screws and check all of your servo arms, linkages, etc… before flying. The rudder and elevator servos are under that bottom hatch and so not observable without unscrewing and removing the bottom hatch. Apparently, when I was setting up the plane, adjusting throws and linkages and such I had neglected to make sure all of these were tight. The servo arms are metal and are a decent fit but slightly loose on the servo shaft. If the teeth are engaged there is zero slop but if you don’t tighten up the servo shaft screw the arm will slip off and rotate out of place… especially when sitting in the trailer, bouncing down the road under the force of gravity I imagine?

So 2 or 3 flights in was doing some stall turns and I was getting adjusted to just the right inputs to get an acceptable looking maneuver when it flopped out of one of my attempts. Since I was low on battery I decided to come down and check out my throws and see if I could improve on the next flight. When I landed, my plane was crabbing slightly toward the pit area so as soon as the tail dropped down to join the mains on the runway I started to feed in just a touch of rudder to straighten the roll out… It wasn’t enough so I pushed in more but nothing occurred. I was far to close to the pilot line and rolling fairly slowly so throttling up without being able to change heading was not an option, especially with a plane I had only a couple flights on and knowing someone was occupying the flight station I was quickly approaching. Instead I hit throttle kill and watched it roll up and bump the flight station. Other than a startled fellow pilot, no harm was done. He maintained focus and control of his airplane and I went down and apologetically retrieved my errant bird.

Of course as soon as I saw the rudder “freely” swinging in the breeze I dug in and found the culprit quickly. I applied just a small amount of nail polish (thread locker is known to attack some of the “plastics” used in servos… Hitec Karbonite in particular but others as well… so I largely avoid it around my servos) and tightened the screw and have had no further issues with this connection since.

Flying with the Power 60 on 6S

The Hangar 9 team recommends the Power 60 for the Carbon Cub if you are going electric and I think they have a pretty good combo here. With my 6S 5000mah packs I believe the plane is capable of handling about anything the real world plane can do, and perhaps a bit more. This does NOT include an unlimited vertical climb with out assistance from the wings but it is not far from it.

My impression is the plane flies just a little “heavy” on the wing and thus requires a bit more speed than I would like, but keep in mind I fly mostly very light, overpowered aircraft like my EF Laser on an Xpwer 35 and 12S, the Timber X on 4S, the Uproar on 4S, etc… For a war bird guy, this thing would probably feel lighter on the wing than most and most scale pilots I suspect would see it as being “about right”. You have to remember that while it has “Cub” in the name it is NOT the ubiquitous yellow J-3. It is not a floater that is hard to get on the ground but it is predictable and smooth. If you incorporate the flaps into your landings (as you should), the plane will land at a very manageable moderate speed with only a little time spent with the tail still flying after touchdown. It’s not a total kitten either in the air or on the ground but in return it is a very capable flyer and a beautiful airplane both close up and in the air.

December 25, 2020

Top Flite 60-90 size P47 ARF… Gas to Electric P4: Flying the P47 with Electric Power!

After completing the power conversion of the Top Flite P47 to electric power it was not long before I had the opportunity to put some flight time on the bird. In the course of a couple weeks I put around 10 flights on the Jug. I’ll relate some of the issues and fixes, impressions and performance information in this article. I don’t recall exactly in what order all this occurred or was measured so I’ll just hit the various topics without trying for any sort of linear time line… my memory just isn’t that good!

First, I’ll draw a comparison to my “outgoing” Thunderbolt, the FMS 1500mm P47. While I’ve always enjoyed flying the FMS aircraft and would recommend it as a smooth and good flying airplane, I prefer the Top Flite in the air.

While just a few inches larger in wingspan and several pounds heavier, it just seems to fly more like a warbird… in only the best ways.

Neither are hard to land. The FMS can land slower due to wing loading but also due to just being a lighter aircraft it tends to bounce around a bit more. The Top Flite likes to land a bit hotter, even with flaps but it settles in nice and rarely wants to bounce. The FMS may be a bit more aerobatic, but either can do anything a real jug can do plus more and the Top Flite seems to just track better and slice through the wind better. Everything it does is smooth where the FMS can occasionally be a bit more twitchy. Not terribly so, but noticeable if you fly them back to back.

Of course it may not be a fair comparison considering the power system differences but my Top Flite is certainly faster and looks it even though it is a bit larger (my experience is larger planes actually look slower). I always thought the FMS looked a bit slow in the air considering it’s a fighter plane. It certainly flies well even at slower speeds which is nice on approach but without making some changes it was never going to keep up with the Top Flite.

The other big difference between the two is flight time. Unexpectedly the bigger Top Flite can loiter much longer than the FMS. I figured using an 8S system would give me higher speed but at the cost of weight (the Top Flite is heavier even if it was only running a 6S) which would balance out and result in the same 6 minutes or so down to about 30% in the packs that the FMS typically did. I’m running the same 5000mah capacity, just more cells. Instead, as I recall, I landed at 6 minutes and had 60% left in the batteries on the first couple flights!! Now on those first couple flights, I probably wasn’t pushing it quite as much as I normally do the FMS but the flights since have convinced me to up my timer to 7 minutes and even with some more aggressive flying I am landing with 45% or more of the battery capacity remaining… I’m not really sure why I get such great efficiency but I’m going to try bumping up the prop size a bit to get a bit more punch and see how it affects things. Nothing is getting overly hot as is so I’m hoping for even more power and still having a 7 minute flight to 35% on the batteries…. we’ll see.

Aside from the flying characteristics I have made a few other changes/repairs on the Top Flite P47. After these changes it has completely replaced the FMS which I recently sold to another pilot.

First of all, I noticed that one of the flaps on the Top Flite could only extend to perhaps half of the recommended travel so I had to setup with that as the max flap throw. On the first flap assisted takeoff (with about 65% of available travel), all seemed OK but on landing with full extension I was disappointed with the effect. Other flap equipped planes I’ve flown certainly slowed up and assumed a nice sink rate where the P47 did not slow as much as I was hoping with the available travel. On closer examination it certainly appeared whomever had glued in the hinges had gotten them a bit to tight, which was causing the push point hinges to push against parts of the wing trailing edge. With some judicious trimming I got closer to 75% of recommended travel but no more. It was all I could get without cutting the hinges and starting over. Happily, it was enough that on the next landing the Jug slowed up significantly and dropped in a bit slower. I wouldn’t mind a bit more flap but it’s now very manageable on landing. It likes to land a bit fast, but that is very typical warbird like flying.

I still land a bit faster than I really have to as I’m really still just getting familiar with the way it flies and particularly how it lands. At one point that certainly bit me. We have a nice Geotex runway at our field about 250′ long and I love to land on it when I can. Partly, I just like to control the plane and land it where I choose versus just letting it land. I also feel like the landing gear is less stressed when it doesn’t have to drag through the grass. Putting the plane down “on target” is a good skill to perfect as it can come in very handy when conditions are less than ideal or when landing at facilities that don’t boast our 700′ well manicured grass runway with almost unlimited approaches! On the particular landing in question, I came down a bit fast due to some crosswinds (it’s easier to bring it down fast and maintain control all the way to the ground) and I was rolling tail high, holding a bit of rudder to offset the wind when I rolled across the one flaw in our Geotex runway… a little ridge where the grass edge of the runway used to be. This popped the plane back up in the air just long enough to carry the plane into the grass. Once in the grass I tried to let it settle in but the sudden transition from tail high rolling on grass to the same in the grass caused a quick nose down rotation as the wheels touched back down and she did a flip over on her back…. just hard enough to snap the top couple inches off the rudder! In retrospect I should probably have juiced it a bit and slowed my decent or even gone around but all in all it was ugly and embarrassing but it was a fairly clean break and an easy repair. It also broke the prop which was more expensive to fix but otherwise she was unhurt.

The other occurrence during these first flights was when the battery hatch decided to do its own “off field landing”. I was not a fan of having magnets in the front of the hatch and pins in the rear as this was built but I decided to give it a try. In order to keep the hatch in place I took the liberty of attaching a couple more magnets inside the body to increase the pull of the existing setup. This certainly seemed to help it really snap into place, but apparently that was not enough as around flight number 4 I landed with no hatch in sight! The really odd part was that I didn’t get unusually high or far away and at least 2 other people will swear they never looked away during the flight, yet all agreed the hatch was attached on takeoff and no one saw it come off but it surely was not on the plane on landing! Again, I was frustrated as the hatch was such a nice feature and creating a proper curved replacement was not something I really wanted to spend a lot of time on but I had no real choice. The new hatch now has this latch centered on the leading edge and I don’t believe it is going to part ways quite so easily in the future.

With that taken care of there are a few “clean-up” items I want to address. The cowl is a bit hacked up as it was cut to allow for the DLE-20 and of course you can’t buy a spare for a plane that hasn’t been produced in a number of years… I’ll have to figure out if I can find something available that fits, or if I will try to repair what I have.

A second item is that the cockpit is empty and I would love to find a nice pilot figure that looks appropriate in size and style. I’m eyeing some “Benchcraft” warbird busts from Motion RC. At the price, I will probably order 1 or 2 and see what looks good.

In the meantime this is simply an excellent flying airplane and a great power setup that I’m really enjoying. I’m very happy that the stars seemed to have aligned on this airplane.

December 15, 2020December 17, 2020

Top Flite 60-90 size P47 ARF… Gas to Electric P3: Motors, Speed Controllers and Batteries

This is part 3 on my journey of converting this aircraft to Electric power. To see the previous post on the topic, click here.

As I have mentioned previously, I had picked up a nice Hacker motor from a flying club member and it seemed like it might work out as a power plant for this aircraft. I needed to get that mounted and also figure out what sort of ESC might be appropriate as well as selecting an appropriate battery and then figure out placement and mounting for all of that. So here was my process.

First I researched the airplane, including expected weight, wing area and ground clearance. I also read a bit on any balance issues folks reported to see if I was likely to need nose weight or tail weight and the weight of the suggested power plants. Armed with that I logged into ECalc and filled in the blanks with the wing area, weight and the motor type I had on hand. I then started plugging in appropriate speed controllers, props and battery combinations to see what I was going to need to get a good power to weight ratio. Something in the 1.2:1 or higher range seemed like a good goal for a fighter aircraft like the P47!

I like to keep the voltage high and amperage low in an RC aircraft power system. Higher amperage is hard to accommodate as most of our common connectors are not rated for it. If you overtax them, they get hot and waste power and eventually this causes a catastrophic failure. For similar reasons, our LiPo batteries will fail quicker when you run demand high current rates from them, plus they cost and weigh more as you try to accomplish this with batteries that have a higher “C” rating.

A little rant about LiPo C ratings… Feel free to skip the next two paragraphs if you like.

In general, C ratings are useful only in that a higher C rating within a manufacturer battery line indicates the ability to supply more current without damage to the battery than the batteries with lower C ratings. Beyond that they are deceptive at best and almost useless for comparison between manufacturers. Feel free to disagree but I am convinced that this is the state of things at this time and don’t expect it to change anytime soon so don’t put to much faith in C ratings.

So, while my large aircraft could (according to the manufacturer C rating) run on 20C cells, typically 40C cells get pretty hot and therefore fail sooner rather than later. The 50-60C packs simply perform better, don’t get as hot and outlast the lower C ratings… at least in the brands I most commonly run. I don’t bother to purchase from companies who advertise 100C and better as they are pure fiction in my opinion. A continuous draw at the advertised C rating is almost always a recipe for battery destruction in very short order and in the case of larger capacity packs is likely going to result in batteries dying from internally generated heat and wires/connectors or something similar failing anyway as the system quite literally “melts down”! It’s a joke to say you have a 4000mah 100C pack (that equates to 400A draw) and then putting a connector on it that is rated to handle, maybe 100A for short periods before it literally “melts down”! The cells in these packs might handle 150A draw with perfect ventilation but I doubt it. OK, rant over.

Back to sizing the system I came to the conclusion that running an 8S system with a 16×10 prop would be a good starting point with a predicted 1.3:1 thrust ratio. Partly this choice was based on the power I wanted and partly due to available speed controllers. Spektrum had just released a line of Avian speed controllers and one of them was capable of 8S (which I estimated was close to the biggest packs I could likely get into the airplane) and was rated at 80A continuous with 100A peaks which was as much as I really wanted to run through the EC5 connectors anyway! It was also far less expensive than the Castle Creations options in this same range and had Telemetry built in that I was going to want. I can do that with Castle Creations and most other speed controllers as well, but with even more expense. This setup also allowed me to prop up a bit for additional power if I later decided I needed to, which is always a nice option to have. The tradeoff if I did was that a 16×10 would likely give me 7 minutes or more in the air with a 5000mah pack while a 17×10 or 18×10 would start to cut into that as they would draw more amps.

In order to take advantage of the telemetry capabilities I wanted to access from the Avian speed controller I also would have to acquire a new receiver. I settled on a new AR6610T. That wouldn’t be a terrible expense as I had a project that needed a simple receiver like what was currently installed in the P47 so one way or another I was going to be buying one soon anyway.

Decisions made, I placed some orders and started looking to mount the motor. This came down to simply finding the right size spacers and then a hole for the wires to get through the firewall and some judicious trimming of the dummy engine.

The spacer length I needed turned out to be the same as some readily available standoffs for a DLE 30, which simplified things a bit.

Then to allow the prop to clear the cowl I added a couple washers behind the prop collet assembly.

Accommodating an already existing 6S 5000mah pack plus a 2 cell pack of equal size and rating in series (which the speed controller accommodates simply as it already has a series harness attached!) was a bit tricky as the tray exposed under that hatch was simply too shallow for this setup and I didn’t want to buy several batteries for which I would have no other use. Here’s the original space.

So, I did some cutting and regluing to create a “ramp” that allowed for easy insertion of some of the packs I had. I had already determined that having the batteries up against the back of the firewall was appropriate to get the balance where I wanted it and while it was a bit tricky to cut out, the existing structure, thusly relocated, works well for the new battery compartment “floor”.

I needed some 2S “booster” packs (as I think of them) to add to my 6S packs in order to run an 8S system so I started looking for something appropriate. I ended up with some APower branded 5000mah, 60C rated packs I picked up from RCBatteriesusa based in Arizona. I had read an article about the company recently and decided to give them a try. They are not the cheapest place to buy packs, but not at the very high end either and offer a good warranty as well as being reputed to have top notch service. The folks there were as good as advertised in taking care of what I wanted, including the fitting of my requested EC-5 connector even though that was not an option on the web site when I first started shopping. At no additional cost I might add. After unpacking, examination and a few cycles they appear to be high quality.

That about covers the power system… I think. Next time I’ll try to run down my experiences and impressions of the first dozen or so flights.

December 1, 2020December 17, 2020

Top Flite 60-90 size P47 ARF… Gas to Electric P2: The Hidden Battery Hatch

For Part 1 of this article, click here.

It was the wee hours of the morning before I really made the firm commitment in my mind that the P47 had to make the conversion to Electric. At the next opportunity I started the process.

First order of business was to pull all the gas accoutrements from the airplane. First, I pulled the prop and cowl and started stripping out the gas motor mount, ignition and the supporting switch, battery etc… I knew a guy who was looking for a DLE-20 so I made him a deal on the engine to help finance the needed items to complete the conversion. I had the motor but needed a speed controller and maybe some additional lipo packs.

As soon as all that was out of the way it was time to explore the “hidden hatch”. For reasons that are beyond my comprehension, Top Flite built a hatch into the top of the P47 (and other models in this line of ARF warbirds). They framed it out in ply, put magnets in place along with pins to hold it in place… and then put a solid balsa sheet skin over the entire nose (including the hatch) and covered it with no markings or indication that it existed. Nor is it documented in any way in the manual!

With no guidance it became quite the task to figure out how to outline and cut the hatch free. What I eventually settled on was to take a pair of forceps with an extremely sharp needle locked in it’s jaws and reach down into the wing saddle and force it up between the two plywood plates at each end and side of the hatch until it emerged through the covering. By doing this repeatedly, working my way around the hatch perimeter I outlined the hatch on the covering. Then while holding my breath, holding my head at just the right angle and sending up prayers to the modeling gods (a more fickle lot I have yet to meet) I took an Xacto knife and inserted it into one of the pin holes and slid it by feel between the plywood plates. Working my way around the perimeter of the hatch, I managed to slice my way through the vast majority of the sheeting. With the judicious use of my razor saw, I got the hatch loose with only one problem… I managed to cut through the pins at the aft most part of the hatch!

Don’t worry about the wasp decal… I was planning on ordering replacement graphics anyway!

As you can see it wasn’t a perfect cut but it came out well enough!

Luckily, I had on hand an appropriate sized dowel and replacement of the pins proved to be a fairly minor task. I would later go on to add a hatch latch on the leading edge of the hatch… or at least on the new one I had to build after I found out the hard way that those magnets just aren’t strong enough!

Next time I’ll discuss the power system choices I made and how that is working out.

To see the next post on this topic click here.

November 29, 2020December 17, 2020

Top Flite 60-90 size P47 ARF… Gas to Electric P1: Decisions

I already posted a bit here about this airplane with the focus on the retracts I used. You can see that post here. This post will focus more on the Electric conversion process and the results of that. Note that I never flew the plane with the DLE 20 that was on it when I acquired it so can’t compare to that… I can only tell you about my conversion process and the results I got.

Acquiring the airplane

I have a flying buddy that has been in and out of the hobby for the past several years named Martin. Martin called me after not having heard from him for a bit (maybe a year or more) and reminded me of a P47 that we had worked together to get ready to fly. It was a 60-90 size Top Flite ARF and we had gotten it pretty close to flyable with a DLE 20 installed, servos and linkage all installed and even radio gear all in place. For whatever reason it had just never made it into the sky.

Martin asked if I was interested in the airplane. If you look back at my previous posts you will see that I already own a nice FMS 1500mm P47 that flies very well on 6S. While I have a particular affinity for the P47 (my grandfather helped build them in Evansville, Indiana during the war) I was hesitant because this airplane is only slightly larger than the foamy I have and I wasn’t sure I really needed two P47s in a very similar size… plus I’d have to consider whether to convert it which might be quite a job. Add in that I really didn’t have any room in the RC budget at that moment for another airplane and I explained to Martin that I really couldn’t give him nearly what it was worth. Martin however, explained that he simply wanted to get out of the larger airplanes like this and since I had spent so much time working with him on it, he was simply offering to give it to me! I offered to at least pay something but Martin insisted that if I had an interest that it was mine. He even offered to deliver to the field in a couple days when I was planning to fly. What could I say? Of course I accepted.

Here’s what she looked like just after delivery.

Modifications and Decisions

After a lite cleaning and a thorough inspection I made a couple decisions on things I wanted to change/upgrade or just tinker with a bit before I’d fly it. A couple were easy decisions.

First, I wanted to order a new set of graphics as the decals the came with the plane I knew would never last. In my experience if you want good looking and long lasting graphics with few/no wrinkles or bubbles you buy vinyl… typically from Callie Graphics. Callie is inexpensive, willing to work with you on any request and provides a great product. I had a set of markings on a 50cc size Mustang for 3 or 4 seasons. Many days the plane sat out in the sun all day and the vinyl never bubbled or faded. I even had to peel the stars and bars from the wing and reapply them when I crashed the bird and bought a new wing. They still looked like new when I sold the plane a few years ago.

Second, I knew I wanted to replace the landing gear, which I’ve already discussed.

The third issue was much more of a question and it took a couple weeks to come to a conclusion. What to use for power? Obviously leaving the DLE 20 in place would have been easy. I knew the history of the engine and that it ran well before it came to be installed in this bird and it would certainly be an adequate power plant. However, every other plane I currently own is electric and I had what I thought might be an excellent motor for the purpose. In fact I had been looking for something to put the motor in ever since I acquired it.

Thus began several days of reading and research. First I looked on various discussion groups about the airplane and what others had done. 90% plus had run gas engines… a few 2 stroke glow and a few 4 strokes rounded out the vast majority. What intrigued was the 2 guys who mentioned they were running electrics. Eureka! Until I realized that there was just no easy place to put a battery hatch into the P47… at least not that I wanted to tackle. the plane is pretty much all curves and being an ARF, access is limited unless you want to recover and rebuild extensively. This didn’t seem promising.

While I mulled on that, I started to look into the electric motor I had and tried to figure out if it would be enough power for the P47. The motor is a Hacker A60-5S-V2 and while the Hacker site has a fair amount of info there was only a bit of corroborating information that I could find. It looked like it might be just a bit on the small side if you believed the Hacker site information. Encouragingly, the actual users reported fairly uniformly that they were running this motor (and most Hackers it seemed) at the maximum ratings and even significantly above with no problem at all. I picked up this motor at a swap meet NIB from a trusted source at about half the price of a new one… I could never bring myself to pay the full price when there were a lot of quality motors available at much lower prices… Could the Hackers really be that much better?? This was my chance to find out, right?

With 90% of my previous electric setups I was always able to find a dozen examples of similar planes and power plants to compare to. In this case, only a couple examples were out there… so lacking enough information to confidently pick a proper propeller and speed controller I decided to revisit an old standby… eCalc. I won’t go into great details, but based on what it showed me I decided that the Hacker could “hack it” on the P47. I might need to use 8S batteries (which I have none of) and the flights might be a bit shorter than I’d ideally like (6-7 minutes predicted) but I really wanted to try out this motor.

So that issue aside I was back to the problem of a battery hatch… I went back to all the groups and started reading again and after several hours of reading and making the firm decision to just keep the DLE-20 in place, I read a few more posts and one of the guys who was running electric power mentioned the hidden hatch… WHAT!? I read on for hours and found nothing but then I saw reference that the hatch existed on this entire series of warbirds?? It was only 1AM by this point and I had to get up at least by 6 but this was important, right? As I continued my research, I found a description of where the hatch was located and how to open it up on the sister warbird, the Mustang. A quick trip to the shop and I confirmed the hatch did actually exist on my P47 as well… sort of… and the decision was made. I had to try.

To see the next post on this subject click here.

March 30, 2020

UMX P-47 Electrical Issues Resolved

I received this UMX P-47 as a Christmas gift a couple years ago. I have a warm place in my heart for the P-47 as my Grandfather helped put thousands in the air while working in the Republic plant in Evansville, Indiana. I checked the markings and this model is based on an Evansville bird! Excellent.

Here is what the little UMX looks like:

The P-47 was one of the primary work horses of WWII. It was a favorite with a lot of pilots as it offered that most favored of qualities, survivability. With plenty of armor protecting the pilot, a reliable air cooled engine and (as long as you had altitude) a dive speed that almost no other plane could match providing an escape if worse came to worse, a lot of pilots survived missions in a P-47 that would have had different results in other birds. This led to a popular saying during WWII “If you want to get the girl fly a P-51, if you want to go home to your girl strap on a P-47.”

It was also heavily armed with 8 fifty caliber machine guns and could carry 3400 rounds of ammo along with an impressive load of bombs equal to more than a third of what the B-17 bomber could carry and so became a favorite with the ground troops as well, providing a lot of support to the boys below.

For all these reasons, I love a P-47 and though I don’t get to fly it often I do enjoy it. It flies well for its size, is fast enough to look like its doing what it should be, and it tracks nicely, I’m sure partly due to the on board AS3X stabilization. It requires a good size space to fly indoors and can’t take too much wind so outdoors is limited, thus the limited flying time.

Starting last year I’ve had the opportunity to fly at one indoor venue over the winter months that is large enough to enjoy flying this bird in. It was during one of these events that I started having a weird issue with the aircraft.

Occasionally, the bird would suddenly and completely lose power while taxiing. This happened once and I thought I just had a bad battery. The second time it started working again when I picked it up and re-plugged the same battery… odd. After that flight it went back in it’s portable hangar and sat for a couple weeks ’till the next indoor at which time I took it out and tried to fly again… It was only when the spark happened as I plugged in the battery that I recalled the previous issues. I quickly disconnected a rather warm battery… YIKES! A close examination of the area helped locate the issue…

As you can see, the insulation has pulled back and several strands of the multi-stranded wire are trying to make some “non-approved” connections!

To cure this problem I first cut off the remaining strands and then reattached them with the use of my handy “helping hands” soldering clamp.

Once that was accomplished I used some liquid tape to insure that no more unapproved connections were going to occur.

Then to help further protect the connection I applied some shrink wrap. Here’s the final product.

I’ve since gotten 4 flights on the “Jug” without issue. Unfortunately, with the recent outbreak of Covid-19… further flights are probably months away, but I am happy to report that the P-47 is back to mission ready status. Here’s hoping we can all be healthy and back to this wonderful hobby soon.

January 15, 2020July 27, 2020

Hangar 9 Carbon Cub 15cc ARF … Part 2

One of the first things I’m always concerned about with an RC airplane is just how easy it is to get flying once I get to the field. I really don’t want to be fiddling with 15 bolts and nuts that require special tools to attach, nor do I want to have to crawl around on the ground to assemble the airplane, etc… At least not if I have a choice.

With the H9 Carbon Cub I felt like it was going to just be to “fiddly” to assemble as designed from H9. The wing attachment method with screws that would have to be put in from the bottom of the wing, up in a hole and then adding in the wing strut bolt attachments, the battery placement and mounting method which was going to have to be done reaching under the wing and into the cockpit area and then a screw inserted to hold it in place?? Did they really think I was going to do that for every flight? I found it frustrating to do with no windows in place and the cowl off! I certainly didn’t want to try this reaching in only through the door on the side of the cockpit.

All of this screamed out for some modifications so here is what I went with. First, I decided that I wanted to reverse the wing mount tabs. IE. I decided to permanently mount them in the wing and make the body end be the area where any attachment task was done. To accomplish this I needed to remove the tabs from the body. This was fairly quick and easy with the proper application of a ball peen hammer. Here is one still mounted in the fuselage.

They have a shoulder on the inside of the fuselage so you need to push them into the plane body if you want to remove them. A few raps and they pushed into the body and were easily removed.

A tiny bit of wood came off with them but not enough to cause any concern. I then used the phenolic tab material as a pattern to make replacement pieces out of similar thickness aluminum. Since I want them to extend a bit further into the fuselage so I can attach them on that end, each of mine are about 1/2″ longer than the originals and don’t have a tab. I did drill the hole so I could attach them to the wing (I just intend to only do this once)!

Once all cut out and the hole drilled in each I did some sanding to round the corner and cut some slots into them so I would have a way to pull them together to keep the wings from sliding on the wing tube and opening up a gap between the wing root and the fuselage.

Even with this mod, I didn’t want to have to reach up into the cockpit through the door and put screws in, rubber bands on or attach a tie wrap or whatever. Between this and the need to swap out batteries I decided I wanted to have a removable top window.

This meant I needed to build some sort of frame to mount the window in and create a hatch assembly. This sounds easy until you realize that the top of the cub is a curved surface AND the opening narrows as it goes toward the rear of the airplane! So first step was to make some custom shaped window frames for each side. I began by tracing the shape onto some light card stock (sometimes having a greeting card crafter across the shop comes in handy!). I then proceeded to attach the template to some wood and then cut and sand to shape.

I then used some of my finer TLAR engineering skills (That Looks About Right) to make a rounded cutout in the bottom of these pieces in order to provide clearance around the wing tube. After that I cut a couple of appropriate length 1/4″ square sticks to use as the front and back. Each of these is custom of course due the aforementioned narrowing of the opening.

Once that was all completed and some careful fitting done, the frame was assembled (I laid all the pieces in the place in the top of the fuse and used CA to tack glue them together then removed them from the airplane and finished the gluing process).

After a test fit of the full (one piece) window, I carefully marked and cut off the material for the top window. Before attaching it, I colored the frame with a black permanent marker and then glued and clamped the window material to the frame with canopy glue.

This was allowed to dry for a few hours and then the clamps came off and I added a bit more glue around the inside edges to make sure it was not coming off anytime soon. From there I started working on ways to mount the frame to the top of the airplane. First I made a tab out of a couple pieces of popsicle stick and glued it to the front bottom edge of the frame at an angle so it would catch the front of the fuselage. This prevents the front from lifting. You can see this here.

I had to just do a bit of adding a layer of popsicle stick and then sanding a bit off to make it have a close enough fit. More black marker to cover up the wood grain took care of hiding it.

The final stage involved another stick of wood on the back edge of the frame to add some “meat” to the frame (my original 1/4″ frame I felt was just to small) and allow for the attachment of a “handle/antenna” for easy removal of the top hatch when needed, along with a block of wood to house a magnet to hold down the trailing edge. Adding some black pin striping around the edges to give it a truly finished look was the final step in building the top window/hatch.

After all this was said and done I decided with this easy access I could use a turnbuckle to hold the wing panels together. Its very quick and easy to put in place and because of some fitting issues at the wing root of the port wing, I needed something to put a fair amount of pressure on to hold the wings where they belong.

Here are a couple shots showing the final product. I feel like it came out pretty decent and I wouldn’t have been happy with the original setup.

Next time, I will discuss the bottom air vent I decide to add and a couple of other minor adaptations I made.

January 8, 2020January 15, 2020

Hangar 9 Carbon Cub 15cc ARF … Part 1 of ???

A couple months ago my flying buddy Gary picked up a Hangar 9 Carbon Cub 15cc ARF that someone else had begun assembly on. After he had done a bit more work on it he decided it wasn’t for him so I acquired it in turn. I have always thought it was a beautiful airplane and wanted one so while I’m not sure how good a flying craft it will be, I decided to give it a go.

First, I had to decide what I would power it with. For me that was an easy decision. I doubt I will ever have another glow engine… expensive to run and messy. Other than having good memories that pop up when I smell hot glow fuel, there’s just no good reason I can think of to put one on an airplane these days. I may do another gas powered RC airplane one day, but not glow. It doesn’t hurt that I happen to have a slightly used Power 60 and 100A Castle ICE sitting in a drawer. Decision made, I started going through the manual and deciding what still needed doing to get it flying.

In addition I needed to go over the airplane and see what the previous owners had done that might need some attention. I also started researching the airplane online and noting what I might want to add or modify. So far I’m still not quite to full flight status! Like most of my builds, this one has been interrupted, delayed waiting on some parts or just to give me time to decide how I wanted to do things, and has taken about 10 times as long as the manual suggests! I’ll start to add some articles soon detailing the changes/issues and challenges I’ve had getting the Cub ready to fly.

August 8, 2019January 16, 2020

Mini Convergence VTOL – First forward flight, and first repair!

Back around Xmas a relative gifted me with a nice little micro flyer for indoor use. It was definitely a beautiful little plane… as a matter of fact it was something that I liked so much that I had purchased one for myself just weeks earlier! So back to local shop I went to make a trade… and on a whim I picked up a Mini Convergence VTOL from E-Flite.

I flew it a couple times over the winter at some of our indoor events but I was not about to try forward flight in the limited space available so it sat mostly unused through the winter and for most of the summer before I really recalled it was over there in the corner in a pile with my other indoor flyers! After I dug it out and charged some batteries I took it out to the field, rechecked all my programming to find the right switch setting to get into a forward flight mode and lifted off.

Forward flight mode went well and I was getting a pretty good handle on how the plane handled life as a fixed wing when the radio timer started warning me I should start to think about landing. I slowed a bit and then flipped the switch to go back to vertical flight mode when things started to get “interesting”.

The plane began to immediately flip end over end and no control input made a lot of difference. It didn’t fall very fast but all I could do was throttle down when the ground came up to grab the airplane.

Back on the bench here is a view of the culprit…

As you may have noticed there’s something missing on the rear motor… two things in fact. The prop and the spinner nut! No wonder if flipped end over end! There were also a couple of foam “piercings”. One in the wing and one in the canopy. Neither of those are any real concern.

Luckily the bird comes with two spare props. The rear prop, I found, is the same as the port/left prop. This has it’s pitch in what I would consider the “standard” direction for aircraft with a counterclockwise rotation creating rearward/downward thrust. Luckily, I just happened to have an aluminum prop nut/cone with the correct thread in the shop and the plane comes with one of each type of spare prop so that problem was quickly solved.

Unfortunately when I powered the plane back up I quickly found another issue. The port side motor did not rotate up into the same position as the starboard.

I quickly realized something was not right with the servo that performed the “tilt” on that motor. Opening it up, you can see why.

To get this view I had to remove that servo which required removing a couple screws to get the servo unmounted and a few more to remove the plastic faring that covers the bottom of the boom. Also, I disconnected the linkage and finally I had to split the tape with a razor blade (careful not to cut wires) and once removed, open up the servo. Some of that disassembly is shown below.

Reassembly had to wait a couple weeks but was not particularly challenging. For once I didn’t lose any screws, linkage, etc. The only real gotcha was to make sure you have taken note of where and what orientation the plug goes into the receiver/main board and be sure to power up the aircraft and allow it to pivot the servo to the starting point so you can line up the servo arm on the new servo so that the two engines are pointed in the same direction for startup.

So, moral of the story. When you read on line that folks have had some issues with the prop nuts loosening up and you should check them before each flight… listen. For my part, I decided to do something to help the nuts stay in place so I put a bit of clear finger nail polish on the threads of all three of the motors before replacing and tightening them down. I find it works pretty well as a thread locker for such things without risking any damage to plastic (like the props). Some thread lock compounds have been known to make plastic brittle over time! It is also fairly easy to muscle the nuts back off with the finger nail polish but in my experience does a fair job of eliminating any loosening due to vibration and the like. IE it can broken free again but won’t generally fail under normal use.

I’ve made one flight since this repair and the aircraft did well. So if you have one of these, do yourself a favor. Go unscrew all three prop nuts and find some non-permanent thread lock (or raid the wife’s nail polish stash) and take out a little insurance.

June 9, 2019July 27, 2020

Balsa USA 1/4 Scale Cub – Part 6: Wing Mounting and Struts

It seems like the work on the Balsa USA Cub never ends. Some of it is just that the BUSA kit seems to be more complicated than most and the way the designer/manufacturer chose to do things sometimes makes no sense to me. Also, since I got this as a partially constructed kit, I’m having to go back over everything to see what parts the previous builder changed, skipped or just didn’t follow directions well!? Of course the fact that I’m “converting” it to a super cub is not helping the process along either!

One of the things I have spent significant time on concerns the wing attachment methods. The original plans call for a couple pegs through the wing roots and two bolts as well to hold each panel in place. In addition the struts are load bearing. They are bolted to the ply plate that makes up the fuselage floor and screwed into hard points on the wing. When I first tried to assemble them I quickly found the whole process to be frustrating and overly difficult. Getting the wings in place and holding them there while installing the bolts was difficult and that was without any windows in place! I can’t imagine what a PITA this would be once the plane was all covered and the windows all in. I quickly realized something had to change. In addition, it seemed entirely possible to cause some damage to the plane while installing the wing struts as the entire weight of the wings at that point is hanging on the wing roots and the structure between doesn’t seem all that strong. Thus the need for load bearing struts!

So I first added a wing tube to each wing and fashioned some bracing inside the top of the cockpit area to give it some strength. Now there is something a bit more substantial to hold the wings while the struts are being installed at the flying site. You can see the aluminum tube in the wing center joint and inside the wing panels below. There is a carbon fiber tube inside.

The strut attachment method seems a bit ridiculous as well with no concession to ease of installation or transport. The vertical wires that connect to the wing mid-point don’t seem to be movable or easily removable so transporting the struts looked to be a pretty interesting prospect. Add to that the directions for attaching the struts to the wing hard points uses wood screws… which to me is just a uniquely bad idea. How many times reassembling this bird before a screw is over tightened, stripping the wood and weakening this critical attachment point?? I understand these kits are designed to be very scale like and that most builders are going to modify all of this to make it even more so. Maybe they don’t intend to fly the plane all that often… but for me, if it isn’t reasonably simple to assemble when I get to the field it will likely get little flight time and become a hangar queen. I’ll take slightly less scale like and more functional and easy to get in the air over scale in this case. BUSA might as well just say “figure out a method that will handle the stresses and that you find acceptable to assemble” , and leave it at that. The directions they do provide seem to me to be a poor attempt at best.

After a lot of fits and starts and coming up with several plans and then rejecting them I came across some struts and connecting hardware from a 1/4 scale clipped wing cub at a swap meet. The struts were far to short but I cut off the ends in hopes of using the attachments.

I don’t know why he had them but the gentleman had 2 or three sets so I picked up a set for myself. I looked at them twice with great regret that they were for a clipped wing cub but then figured if nothing else I could use much of the hardware. Once I looked closely at the hardware the wheels started spinning and I realized the hardware alone was more than worth the price. So I created some Frankenstein struts.

Below is a snapshot of the mid-wing attachment point. Using the threaded “eyelets” with threads tapped into the hardwood blocks in combination with the hollow aluminum tubes with built in attachment points, a 4-40 bolt and nylon insert nut makes for a secure attachment point. The tubes and wires were trimmed and epoxied together after adding some grooves to the wire to insure the glue gets a good grip.

On the other end of the wire, I used some nylon landing gear wire straps and #2 screws to create an attachment point that is both strong and allows for an easy pivot point for storage. This shows them pivoted down against the struts for storage.

At the outer attachment point, the main strut connections are bolted to the hard point with 4-40 bolts and blind nuts. The ends of the wood struts were trimmed to fit inside the aluminum tube ends as well and attached with glue and screws to the wood strut ends. This took extensive trimming and measuring to get the correct length and support the wings in the correct position. Each is somewhat custom! The nice thing is the ends of the struts that I recycled have a threaded rod at each end for fine adjustment.

I attached the outer aluminum ends with expanding gorilla glue and some #2 screws to “pin” them in place. Now I have a nice pivoting attachment point that I don’t intend to disassemble often as the struts can be pivoted down to sit flat on the wing for storage.

Each strut, once adjusted on final assembly, should take only 1 bolt at the attachment point on the bottom of the body and 2 more at the mid-strut attach point in order to easily assemble or disassemble the aircraft and still provide plenty of needed support.

Combined with the wing tubes, which require a single bolt on each side to attach, the entire assembly process shouldn’t take more than about 5-10 minutes and I expect it to be both strong and fairly straight forward to accomplish.

There is still a long list of projects to get this plane ready to fly, some small like hinging of the wing surfaces, and some large like getting the cabin windows, windshield and door assemblies all finished. More updates soon.