Firestar II / Full Enclosure/ Sections

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Includes: Firefly, Firestar, Mark III C, Mark III X, Kolbra, Sport 600, Slingshot, Twinstar Mark II, and Ultrastar
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planecrazzzy
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Re: Firestar II / Full Enclosure/ Sections

Post by planecrazzzy »

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...
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Re: Firestar II / Full Enclosure/ Sections

Post by planecrazzzy »

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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...
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                Gotta Fly...
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Re: Firestar II / Full Enclosure/ Sections

Post by planecrazzzy »

Paper door pattern ...

It works for both sides

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Re: Firestar II / Full Enclosure/ Sections

Post by planecrazzzy »

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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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Re: Firestar II / Full Enclosure/ Sections

Post by planecrazzzy »

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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...
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Re: Firestar II / Full Enclosure/ Sections

Post by planecrazzzy »

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...
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Re: Firestar II / Full Enclosure/ Sections

Post by planecrazzzy »

Hey Guys ,
Paper gets me pretty close.

Gotta Fly...
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Re: Firestar II / Full Enclosure/ Sections

Post by planecrazzzy »

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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 )
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Gotta Fly...
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Re: Firestar II / Full Enclosure/ Sections

Post by planecrazzzy »

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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
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Re: Firestar II / Full Enclosure/ Sections

Post by planecrazzzy »

.
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...
.
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Re: Firestar II / Full Enclosure/ Sections

Post by planecrazzzy »

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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...
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Re: Firestar II / Full Enclosure/ Sections

Post by planecrazzzy »

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....
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Re: Firestar II / Full Enclosure/ Sections

Post by planecrazzzy »

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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
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Gotta Fly...
.
PS "click" on the picture , then magnify to see it more clearly ...ha , clearly
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planecrazzzy
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Re: Firestar II / Full Enclosure/ Sections

Post by planecrazzzy »

'
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...
.
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Sometimes you just have to take the leap
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                Gotta Fly...
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planecrazzzy
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Re: Firestar II / Full Enclosure/ Sections

Post by planecrazzzy »

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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...
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Sometimes you just have to take the leap
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