Firestar II / Full Enclosure/ Sections

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Re: Firestar II / Full Enclosure/ Sections

Postby planecrazzzy » Fri May 15, 2020 2:57 pm

The windscreen has worked good for 13 years ...

I'm finally getting around to adding the other pieces .

Starts with a support tube , I'm not going to weld it so I made it clamp onto the tube .

I off-set it so the hardware wouldn't poke the fabric

Gotta Fly...
.
Attachments
Full enclosure (51).JPG
Full enclosure (52).JPG
Full enclosure (53).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Re: Firestar II / Full Enclosure/ Sections

Postby planecrazzzy » Fri May 15, 2020 3:03 pm

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I made some gussets.
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Using the shear , it helps to clip this flashlight to my hat .
It's one of those free ones they give away at harbor freight .
.
Gotta Fly...
.
Attachments
Full enclosure (54).JPG
Full enclosure (55).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Re: Firestar II / Full Enclosure/ Sections

Postby planecrazzzy » Fri May 15, 2020 3:06 pm

Paper door pattern ...

It works for both sides

Gotta Fly...
.
Attachments
Full enclosure (56).JPG
Full enclosure (57).JPG
Full enclosure (58).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Re: Firestar II / Full Enclosure/ Sections

Postby planecrazzzy » Fri May 15, 2020 3:12 pm

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I wanted the back section in one piece ,
it wouldn't fit both sides on my sheet of Lexan.
making them separate pieces , I was BARELY able to fit all of the pieces on the 4x8 sheet
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Gotta Fly...
.
Attachments
Full enclosure (59).JPG
Full enclosure (60).JPG
Full enclosure (61).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Re: Firestar II / Full Enclosure/ Sections

Postby planecrazzzy » Sun May 24, 2020 8:50 am

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Once again something a 30" shear won't be able to do ....

I rough cut the pieces out of the sheet of lexan, I used different hand tools .(throatless shear works great )

then brought them to the shear for the final cut .
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Well , not the final cut .

That will be looked at after the pieces are all in place .

Gotta Fly...
.
Attachments
Full enclosure (101).JPG
Full enclosure (102).JPG
Full enclosure (103).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Re: Firestar II / Full Enclosure/ Sections

Postby planecrazzzy » Tue Aug 04, 2020 11:02 am

More progress ...

Hmmm, light but strong ...oh , and simple .

Do you know how HARD simple is ...

I'm fitting the angle to help curve the Lexan...

The gusset is a strong place for the door handle to mount .
I wanted at least three points to hold the bottom of the door in alignment , I got four

Gotta Fly...
.
Attachments
Full enclosure (115).JPG
Full enclosure (116).JPG
Full enclosure (117).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Re: Firestar II / Full Enclosure/ Sections

Postby planecrazzzy » Tue Aug 04, 2020 11:09 am

Hey Guys ,
Paper gets me pretty close.

Gotta Fly...
.
Attachments
Full enclosure (118).JPG
Full enclosure (120).JPG
Full enclosure (121).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Re: Firestar II / Full Enclosure/ Sections

Postby planecrazzzy » Tue Aug 04, 2020 11:18 am

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So far every thing has been fabricated with .032 aluminum .

The handle needed to be stronger for safety . I used .06

Notice that the handle overlaps the tube ...After the handle / latch position was set ,

a simple "stop" was made on the tube where the handle rests/overlaps ,

a rivet with a spacer and small washer stops the handle from moving up .
(the "stop" is not in these pictures )
.
Gotta Fly...
.
Attachments
Full enclosure (123).JPG
Full enclosure (124).JPG
Full enclosure (125).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Re: Firestar II / Full Enclosure/ Sections

Postby planecrazzzy » Wed Aug 05, 2020 5:39 am

.
Hey Guys ,
The door Lexan needed support at the lower rear area .

Air flow Might pressure that area , a small piece of aluminum works good .

The door Hinge was removed , the bottom of the hinge was crimped , the hinge "pin" was bent at a 90 degrees at the top.

Its easy to grab , slide out and remove the door
Attachments
Full enclosure (127).JPG
Full enclosure (128).JPG
Full enclosure (129).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Re: Firestar II / Full Enclosure/ Sections

Postby planecrazzzy » Wed Aug 05, 2020 6:13 am

.
Hey Guys ,

I clamped the next piece in place , I have plenty of extra material that I will need to trim .

I have a few options to secure the Lexan...

I'm still trying to figure out what I will do ...

Here's the stuff that I am scratching my head over ...

Could "Dzus" them in ... make 4 or 5 stations ... reinforce the lexan with aluminum where needed.

Could make small , aluminum "Adel" clamps ...or find light Plastic ones , I have some nylon ones that would fit the upper tube .

I even gave thought about using lacing ...like Rib stitching , light , but not easy to remove .
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I like the Dzus....but leaning towards adel style .

I will use nylon hardware (screws and nuts ), so I will also add a couple spots for safety wire

After all ...This is a "pusher"...most things that come off..., go through the prop.
.
Gotta Fly...
.
Attachments
Full enclosure (132).JPG
Full enclosure (131).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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planecrazzzy
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Re: Firestar II / Full Enclosure/ Sections

Postby planecrazzzy » Thu Aug 06, 2020 7:55 am

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I made a few Adel clamps from .032 aluminum. (watch the grain)
I found nylon "cable" clamps at home depot ...
I'll use mostly nylon ...

As I figure out how to fasten the rear piece of lexan ,

I need to figure out a way to get to the fuel tank area ...hmmm , more scratching , starring ...scratching...

Keep in mind...all of this needs to meet the needs of 90 mph winds...and some prop blasting also .
(I've only had her 90 mph once , by accident , smooth air )

Gotta Fly...
Attachments
Full enclosure (134).JPG
Full enclosure (136).JPG
Full enclosure (137).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Re: Firestar II / Full Enclosure/ Sections

Postby planecrazzzy » Fri Aug 07, 2020 6:16 am

Hey Guys ,
I got the rear lexan piece in position , then marked where the tube crossed it .
Lexan will take some bending , I have some Protection from scuffing and it helps with more radius .

This has a good flow line and Fits into it's place easily .
In fact , in the picture , there are no fasteners or clamps holding it in place (yet)
.
Gotta Fly....
Attachments
Full enclosure (139).JPG
Full enclosure (140).JPG
Full enclosure (141).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
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Re: Firestar II / Full Enclosure/ Sections

Postby planecrazzzy » Sat Aug 08, 2020 4:51 am

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Here's a small detail . Its hard to see the clear material .
I don't want the door to lay on the front windscreen ...they will just scratch each other .
I put some tiny screws into 4 of the aluminum rivets ...toothpicks were too loose .
I'm still looking for wood or plastic to replace the screws .

Anywho, it keeps them apart ... its light and simple
.
Gotta Fly...
.
PS "click" on the picture , then magnify to see it more clearly ...ha , clearly
Attachments
Full enclosure (143).JPG
Full enclosure (142).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
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Posts: 1071
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Re: Firestar II / Full Enclosure/ Sections

Postby planecrazzzy » Sat Aug 08, 2020 5:02 am

'
Its hard to tell I did anything ...just comparing pictures 1 month apart .
The enclosure is hard to see , I've thought about paint trim on the inside ...
sounds like time and weight .
.
Gotta Fly...
.
Attachments
IMG_6170.JPG
Full enclosure (145).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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planecrazzzy
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Re: Firestar II / Full Enclosure/ Sections

Postby planecrazzzy » Wed Aug 12, 2020 3:08 pm

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Matching up the other side , I left more plastic to protect the surface on the rear piece .

The Goose likes to come in ...hang around .
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The escape door is hung , its still big and needs trimming
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Gotta Fly...
Attachments
Full enclosure (149).JPG
Full enclosure (151).JPG
Full enclosure (152).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
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Posts: 1071
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

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