Haven't got a great deal done in the last 2 weeks. Been sick with the flu and then had my brother staying last weekend.
Anyway things are progressing with the battery tray/box as you will see below.
After cutting the hole, I wrapped the wooden mockup of the battery with Duct tape and made it slightly bigger all round first with a layer of cardboard. This is to allow for the layers of carbon on the inside and for some foam that I will use to make the battery sit firmly in place and not be subject to vibration.
I used 4 layers of Carbon on the outside.
Once that was done I roughed up the surrounding area on the inside and put another 2 layers of Carbon on there. Overlapping and increasing the strength.
This may sound like overkill but the 7kg battery will weight as much as 42kg when pulling 6g.
I'm going for a double redundancy with the securing of it too.
Next job is to make a cover (again out of Carbon) that will be bolted through the cell on its flanges (4 bolts.)
Then I will put a securing strap over made out of nylon webbing as a backup.
As you can see below the Flap drive box needs the wire extending to reach the cockpit control. The wire that would do that is not included in the kit. It's easy enough to do with some butt splices.
I've also started working on the elevator push rod guides.
These will be mounted in the bottom of the safety cell. Pete is going to lend me a mould for the rear one as the safety cell is not perpendicular to the base at the end. As you can see the nylon bearings would rub against the carbon bracket they are mounted on - so I Dremeled out grooves for them to run in.
Finally the last photo shows the Confor foam I bought which will be stitched into the bottom part of the seat cover.
It is the best way of protecting your spine in an accident. Unlike a car an accident in a plane will often result in the main force being downwards and it is your spine that suffers. Belts are really only good for resisting horizontal force. And negative g :)
A bit pricey as I went for the Duo version with two grades of foam - £67. But well worth it for the safety and comfort factor.
The memory foam in it should make long flights in the Twister more comfortable.
|Battery will sit like this - under baggage shelf|
|Grinding out grooves for the nylon rollers in the elevator guides|
|They rotate freely now|
|Extending the flap drive wires|
|Battery mock up in place - ready for lay up|
|Weighing down the fuselage lower to make sure the battery box fits.|
|All done on the underside with 4 layers of Carbon|
|Inside roughed up ready for 2 more layers of Carbon|
|Confor foam Duo|