Paul
For those willing to build with epoxy, I think, the best would be to
purchase directly made sheets to be glued on rib
Not the cheapest way, but by far the quickest giving a superb result.
https://www.rockwestcomposites.com/plates-panels-angles/carbon-fiber-plate/carbon-fiber-fabric-plate/plate-carbon-fiber-qiso-tri-axial-gloss-matte-48-x-120-x-0-050-inch-thick-options
pascal Virlouvet
Thanks Pascal
I have the wing rib problem decided. This is a Teflon mold .75 inches
thick. The procedure is wet out the fabric and place it over the center
piece hole. Press the rib form into the center mold. the flanges will be
automatically formed. Put it in an oven set to 200 F.
Let cure.
Teflon is good to 500 F.
Each rib will be precisely the right size. Cut a hole for the spar and
use sort pieces of carbon fiber angle to bond and pop rivet the rib to
the side of the spar.
This will be much faster then making each ribs out of foam and covering
it by hand with fabric glass or carbon.
Patent applied for :-)
Paul Lamar
Very nice. It seems feasible to do the spar locater hole the
same way at the same time. Cut an X in the hole and put plug in.
Michael Nash
A little problem with that. The dimensions of the spar will vary
due to load on it. Top and bottom will have varying layers of uni.
A list of spar hole dimensions should be mad for all the rib locations.
Here is a stress diagram for a typical wing load more or less.
Paul Lamar
Paul the point of the built up spar is you can vary the ply schedule to
get the strength you want over the spar with the same outside diameter
or even easier with the box spar. Then all your rib holes can be the
same size for easy molding
Bill Jepson
Yes all the ribs are the same out side dimensions.
If made on a SIMPLE square tube male mold the thickness of the caps
would step down starting at the root rib. You can start with an off the
shelf cured square or rectangular carbon tube.
If all the holes in the ribs are the same size the spar then must be
made in a female box mold.
Lets call it a square tube female mold. How do I lay up inside a 20 foot
long square tube?
Not possible of course. Or at least extremely difficult.
OK say I made a rectangular male mold that was tapered in height.
The small vertical dimension was near the root rib where the caps are
thickest.
Could be carved out of 20 ft long blue foam I guess. Could also be made
out of four ten foot long steel or aluminum bent up tapered channels and
welded up.
Kind of tricky getting the right taper. Probably calculate the proper
number of ply schedules and then adjust according to needed height.
The next problem is cutting the square holes in the rib plies before
saturating and molding. That is not practical. Particularly in carbon.
Plan B. Makes two part ribs. One front one rear twice the rib lay up time.
That will also work.
Nay.
I would rather cut different size holes in the cured ribs :-)
Lots of options.
BTW the cost of solid Teflon is out of sight.
Garbage bag material can be used as a mold separator with a plywood mold.
The same stuff you use to saturate the fabric.
Add a couple more layers before you put in the plywood mold.
Room temperature or 150 F max in oven cure. Otherwise the garbage bag
might melt :-) .
The actual plan form I intend to use is that of a C182. The 2/3 span
center section is straight to accommodate the fowler flaps and the outer
panels with the ailerons are tapered so those ribs are not all the same
size. I am doing that for the known excellent handing and stall
characteristics of the C182.
No point in reinventing the wheel and do all that R&D on handling.
Paul Lamar
Paul,
Love your ideas, but I would prefer a pusher, remember the Italian
flying Boat, the radiators up front, max cooling.
Milo Burrows
How about both?:
Boyd Thompson
That is the beauty of the turbo rotary. It will put out as much power as TWO
aircraft engines at 650 HP and weigh less than 200 pounds in the
bargain with
out the gear box. Gear box is roughly 50 pounds. That says a lot about the
shear robustness of the Mazda rotary. It is atomic bomb prof :-)
Watch and listen to this video.
Paul Lamar
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