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125 Inch Pilatus Porter PC-6 Kit

Started by Lane C., June 15, 2018, 10:39:40 am

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Lane C.

October 06, 2018, 09:12:12 am #165 Last Edit: October 06, 2018, 10:21:24 am by Lane C.
Darrell, I plan on bringing it on the 13th. Hope the weather is nice. Looks like wind forecast is out of the North that day. But, that's OK.
Current Build = F6F TF 86" Hellcat
Just Finished = Meister 118" A6M3 Model 22 Zero
Future Build = BUSA 1/4 Fokker DVII

Lane C.

After taking the UV-20A out again recently, I decided the gear was just too weak for this bird. Am making a new gear out of 1/4 inch piano wire, which is insanely hard to bend! Plus, will find some stronger springs for the struts. Had to buy a new vise to put the bending jig in and then bolt it to the work bench. I managed to bend the wire, but it's tough, I tell ya. K&S doesn't make this jig any longer, so, glad I bought this one 21 years ago at Roy's. Bent one half of the new gear and will make the back half next. Always something to repair.

The new gear will attach slightly different from the old gear. The old gear is lots harder to duplicate as it has more bends.

Current Build = F6F TF 86" Hellcat
Just Finished = Meister 118" A6M3 Model 22 Zero
Future Build = BUSA 1/4 Fokker DVII

Lane C.

Made some progress on the Porter gear. Bent both halves and got them soldered together. Very solid! Still more work as I need to beef up the internal fuselage sides with 1/4 inch plywood. This is where the spring struts come thru. The factory design on this was just about worthless.
Current Build = F6F TF 86" Hellcat
Just Finished = Meister 118" A6M3 Model 22 Zero
Future Build = BUSA 1/4 Fokker DVII

Lane C.

Kept going into the day! Made some hold downs for the new gear out of large steel washers. Drilled and countersunk them for drywall screws. Seems to work nicely. Will use JB Weld to bed the wire into the mounting blocks to really secure them. Soldered the joints again after filing them down to make sure they were really soldered properly. Scrubbed the liquid flux off the joint with cleanser and washed in hot water. Painted the gear in rattle can polyurethane.  Going to work reinforcing the fuselage sides next, where the spring struts go thru on each side. Should have it all finished soon. Just in time for more days of 105 Deg F heat! Haha.
Current Build = F6F TF 86" Hellcat
Just Finished = Meister 118" A6M3 Model 22 Zero
Future Build = BUSA 1/4 Fokker DVII

Lane C.

Got to the fuselage repairs today. Got the left side repaired and improved. That was the side that had the damage. I cut a 2x3 inch piece of 1/4 inch plywood to epoxy on the back side of the fuselage. Had to cut thru the instrument panel to get that large piece of plywood inserted. But, once back together, won't be that noticeable. On the outside, I soldered a steel washer on the upper spring strut to keep it from pushing thru the fuselage side. And behind the washer is another piece of plywood I made a disk to cover the overall hole and to add to the whole impact area. Won't look so bad once painted.
Current Build = F6F TF 86" Hellcat
Just Finished = Meister 118" A6M3 Model 22 Zero
Future Build = BUSA 1/4 Fokker DVII

Lane C.

Pretty much done with the repairs and mods, so, it's a matter of cleanup and paint touch-up. Added a dowel across the fuselage to really keep the fuselage sides from pushing inward under the stress of the struts being compressed. Barry, this dowel is one of your suggestions the day we flew her.
Current Build = F6F TF 86" Hellcat
Just Finished = Meister 118" A6M3 Model 22 Zero
Future Build = BUSA 1/4 Fokker DVII

Barry Ponder

Good work   Now she's ready for a hard landing. Hopefully we won't have to test that. Ha
Barry. 

Lane C.

August 14, 2019, 01:49:13 pm #172 Last Edit: August 14, 2019, 01:51:35 pm by Lane C.
Pushed on to the painting. Primering done. Color paint is next.
Current Build = F6F TF 86" Hellcat
Just Finished = Meister 118" A6M3 Model 22 Zero
Future Build = BUSA 1/4 Fokker DVII

Lane C.

Got the white out and sprayed a couple of coats on. Letting it dry overnight. Then the black anti-glare panel.
Current Build = F6F TF 86" Hellcat
Just Finished = Meister 118" A6M3 Model 22 Zero
Future Build = BUSA 1/4 Fokker DVII

Lane C.

Painted the anti-glare panel black and then clear coated. Ready to assemble all the parts.
Current Build = F6F TF 86" Hellcat
Just Finished = Meister 118" A6M3 Model 22 Zero
Future Build = BUSA 1/4 Fokker DVII

Lane C.

Last thing for today - installed the gear on the mounting block. I bedded it with Hysol and that takes around 18-24 hours to setup in this heat. Longer in the winter. I was going to use JB Weld but since I had plenty of Hysol I used that. Hysol is likely as good or better than JB Weld. In this application  anyway.
Current Build = F6F TF 86" Hellcat
Just Finished = Meister 118" A6M3 Model 22 Zero
Future Build = BUSA 1/4 Fokker DVII

Lane C.

Got all the parts back on and she's ready to fly! If the temps will go down, that is.
Current Build = F6F TF 86" Hellcat
Just Finished = Meister 118" A6M3 Model 22 Zero
Future Build = BUSA 1/4 Fokker DVII

Lane C.

Got to fly the UV-20A yesterday. Got Barry to fly the first round, then I flew her 3 times. Flew nicely and the new gear held up fine, but the spring struts were still soft. I made an adjustment on them which gave more ground clearance. Very smooth flying bird. Even though 42 pounds, very easy to fly.

Barry got a video of some of one flight, but no takeoff. Landed smoothly but a hop caught the prop just enough to kill the engine.

https://www.youtube.com/watch?v=0xuFjiLIUz8&feature=youtu.be
Current Build = F6F TF 86" Hellcat
Just Finished = Meister 118" A6M3 Model 22 Zero
Future Build = BUSA 1/4 Fokker DVII

Lane C.

After flying and seeing Barry's video, it was pretty clear I needed some propellor ground clearance with the Porter. So, To get the clearance and to help slow down the engine from over 7000 RPM, I ordered a synthetic Biela 4 blade prop @ 22x10 specs. This will give another inch or ground clearance than the 24x10 Xoar and help pull down the RPM's. I had a Dave Brown 2 bladed spinner, so cut it for a 4 blade prop today. Now, just needs balancing.  If all goes well, I can have it ready to fly for the All Scale Meet in a few weeks.
Current Build = F6F TF 86" Hellcat
Just Finished = Meister 118" A6M3 Model 22 Zero
Future Build = BUSA 1/4 Fokker DVII

Lane C.

Got the Biela today and did the final fitting to the spinner. Didn't take much after the initial cutting and filing yesterday. Full 2 inches ground clearance now with plane level.
Current Build = F6F TF 86" Hellcat
Just Finished = Meister 118" A6M3 Model 22 Zero
Future Build = BUSA 1/4 Fokker DVII