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Stopped Work - Ziroli Corsair Build

Started by Lane C., November 29, 2021, 08:23:59 PM

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Lane C.

November 29, 2021, 08:23:59 PM Last Edit: Today at 06:54:30 AM by Lane C.
Finally got around to doing a Ziroli Corsair! Wanted to do one for a while and now have a kit ordered from National Balsa. Ordered the cowl and canopy from Ziroli last week and got them today. Going to do her up an AU-1 paint scheme with the light grey and white paint. Sorta like the one pictured below. Will start on it one day soon. Meantime, will show the cowl and canopy.
Current Build = Ziroli Corsair with 70cc Twin

Lane C.

December 01, 2021, 09:39:56 PM #1 Last Edit: December 03, 2021, 07:06:13 AM by Lane C.
For those who might not be familiar with the AU-1 Corsair designation, the following from Wiki may help. Never says what "AU" stands for (Attack?). But it does say its starting designation was F4U-6, as primarily a ground-pounder. First built in 1952. So, still a true Corsair, just with a different designation. According to the Squadron Booklet, not even one known AU-1 exists today. And Squadron adds it was found by pilots to be difficult to fly compared to  previous Corsairs (likely due to the much greater ordnance loading).

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AU-1: U.S. Marines attack variant with extra armor to protect the pilot and fuel tank, and the oil coolers relocated inboard to reduce vulnerability to ground fire. The supercharger was simplified as the design was intended for low-altitude operation.

Extra racks were also fitted. Fully loaded for combat the AU-1 weighed 20% more than a fully loaded F4U-4, and was capable of carrying 8,200 lb of bombs.

The AU-1 had a maximum speed of 238 miles per hour at 9,500 ft, when loaded with 4,600 lb of bombs and a 150-gallon drop-tank. When loaded with eight rockets and two 150-gallon drop-tanks, maximum speed was 298 mph at 19,700 ft. When not carrying external loads, maximum speed was 389 mph at 14,000 ft.

First produced in 1952 and used in Korea, and retired in 1957. Re-designated from F4U-6. A few AU-1's were given to the French Navy and retired in 1964.

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I am not going to add all the underwing hard points for the AU-1. Just using that designation since that is the one I'm using as a paint scheme. Lane
Current Build = Ziroli Corsair with 70cc Twin

Lane C.

After much thought, I am going to use the VVRC 70cc twin cylinder for power. With a advertised total width of 9.5 inches plug cap to plug cap, it will fit the Corsair cowl fine. With 7.4 HP it should propel the 93 inch Corsair fine. I am having Valley View RC add a set of Bowman rings before they ship the engine for a little extra power and reliability? Hope so. Ha. Still waiting on the kit from National Balsa.

Current Build = Ziroli Corsair with 70cc Twin

Barry Ponder

Crabtree aero in full swing. Going to be a cool build thread.
Can't wait to see the wood on the plans.
 Barry

Lane C.

Barry, got the semi-kit yesterday. Big box - 18 pounds. Will go thru it soon to see what National Balsa sent me.

Current Build = Ziroli Corsair with 70cc Twin

Lane C.

Some pics of the semi-kit. I say it looks great! Laser cutting is very sharp and clean, both plywood and balsa parts. The bulk balsa sheet and sticks looks good too. Should make a good build.
Current Build = Ziroli Corsair with 70cc Twin

Barry Ponder

Looks like good wood. Good luck
On the build.
Barry

Lane C.

Barry, the laser cut wood does look good.

Got the Robart retracts and Valley View gas twin engine today.

Robart 150HD8 main gear and 160 tailwheel.

Valley View RC 70cc gas twin. I had VV install a set of Bowman Rings To get the most performance out of the engine. Comes with NGK plugs, muffler set, standoffs, and RCEXCEL ignition unit. Clean little engine.

Current Build = Ziroli Corsair with 70cc Twin

Lane C.

Going ahead quite a bit, got the shop cleaned out and took the 2 DVII's in the house along with the P-40. It's winter and time to keep them in heated comfort. Ha.

Laid out the plans and started making the crutch. This is the basis of just about all of Ziroli's builds. Pretty simple to do and took just a few hours. It's built upside down.

After making the crutch, I need to make a fixture to set the crutch on to add the formers. Will find some material to make the fixture with and proceed to adding the formers.
Current Build = Ziroli Corsair with 70cc Twin

Barry Ponder

And so it begins. Crabtree aero in full swing. It's going to be cold for the new week. Time to get into wood. Ha.
I'm trying to work on a bass boat tank and get it reinstalled Preston is helping me some with the heavy stuff.
Barry

Lane C.

Barry, yes, time to stay inside or in the shop!

Must have not updated this build as much as the one on RCSB. Got a bit more done. Whole lot more done, actually.

Built a fixture out of left over plywood from the bookcase project. Made a nice full length support for the crutch.

Once the fixture was done, began adding the formers.

Once the formers were in place, but not glued down yet, had some work to do on the tailwheel before former F12 could be glued in place. Attached some hardwood blocks to bolt it to and got it all fitted out.

Then came the outer wing bed stringers. Ouch! Lots of work there to get them to curve around the formers. Was not fun. Lots of cuts to the parts were required to get them to fit to the formers. Plus some bending and twisting.  Besides the infamous flaps, this may be one of the hardest parts of a Ziroli Corsair build.


Current Build = Ziroli Corsair with 70cc Twin

Lane C.

January 16, 2022, 08:02:16 AM #11 Last Edit: January 16, 2022, 08:07:31 AM by Lane C.
Flipped her over and added a stringer to keep things aligned. Kinda looks like a Corsair! While I had her upright, added epoxy on the Tee Nuts for the tailwheel mount.

This is NOT an easy build! Lucky for me, on RCSB there is a recent build thread of the same kit with great photos to look at. The Ziroli instructions are just about a ZERO.
Current Build = Ziroli Corsair with 70cc Twin

Lane C.

Flipped back over and added the guides for the elevator push rods. These aren't on the plans except to show how they exit the fuselage. It's pretty much up to the builder how to route them. I don't like this part as it goes SLOW. 

The elevator rods are in, now need one for rudder control. I'm not a real fan of hidden control horns, but Ziroli set the Corsair up that way.

And, the tailwheel steering will use a pull-pull system. Won't need any guides.
Current Build = Ziroli Corsair with 70cc Twin

Barry Ponder

Makes my head spin. Wow. You really have to stay focused. You have the experience to read and engineer the plans. What an undertaking.
Great progress
Barry

Lane C.

Moved the build over to the narrow run table to make it easier to work both sides of the fuselage. With the planes moved inside, I have more room in the shop. I ordered some 1/8" x 1/4" strips for the fuselage stringers from BUSA. The National Balsa kit was a bit light on them. Couldn't find my balsa stripper, so order some and changed them from Balsa to Basswood for a little extra strength. Once I get the bottom side stringers on there, I can sheet the bottom with 1/8" balsa sheet. And move on from there.

I found a photo of one of the Marine Corsairs in Grey over White that I might use as a color scheme. It's something different from the usual 3 color blue.
Current Build = Ziroli Corsair with 70cc Twin