A Cub Update

[Wyandot Jim]

Hey Guys,
I thought it was about time for an update on the Carbon Cub. I spent 3 weeks at Son Trey's house over Christmas. As you can see we got quite a bit done. The Cub is starting to look like a real Flying Machine. We installed the wings, flaps, ailerons, and the big pain the the fitting of the windshield. A bunch of small items that take forever to do and when finished it looks like nothing was done.
Most of the final finishing items SHOULD go fairly easy..
As the little doggie said when it got it's tail caught in the door" It won't be long now"

Since it is painted Red White and Blue like all of our planes the name for this one is "Patriot" That way if things don't work out the way it should. It will become known as "Traitor"

 

[Shotgungibbs]

It looks great! I am amazed at you and your families' talents!

 

[Dave P.]

What makes the windshield so much fun?

 

[Hvymax]

What makes the windshield so much fun?

Making polycarbonate fit without ruining it.

 

[Kevin]

Looks awesome! Do you buy everything in a kit form, or just figure out which pieces will fit and buy them separately?

Then once it’s all done, how do you test it before flying? Know what I mean? Like how do you know it’s airworthy without risking a crash?

Really cool though. Great job!

 

[Chief 101]

Most excellent! Looks handy and useful as far as design also!

 

[contender]

Looking great Jim!

I used to HATE replacing a windshield or nose bubble in a Huey.

 

[jimbo1096]

Dang that looks nice.
I assume it is an EX? How man hours do ya'll have in it so far?

 

[turd]

Looks pretty darn good, Jim. I am really airplane stupid, but is that a 4 cylinder engine w/4 valves per cylinder or an 8 cylinder? I also second Kevin's question, who flies it first? How do you know it is 100%?

 

[Hvymax]

Most excellent! Looks handy and useful as far as design also!

It's probably one of the most established aircraft designs with a few updated materials.

 

[Dave P.]

Making polycarbonate fit without ruining it.

Actually I'd guess it to be acrylic

 

[Wyandot Jim]

Dave P
"What makes the windshield so much fun?"
I will try and explain what goes into installing this POS windshield and will probably forget some stuff.
First after drilling the holes and painting you position the mounting strip /MS that you see next to the blue tape onto the boot cowl. When you think it is in the correct position then drill holes into the boot cowl /BC and temporarily attach the MS to the BC Now you are ready to fit the oversize windshield/WS by putting it on the BC without the MS on so you can see the drilled holes in the BC and the ones in the side post and on top of the airplane frame. In the picture you can see the side frame screws.
Now that you have pushed and pulled the WS into place you mark where you want to cut the WS with the die grinder with a thin cut off wheel on it to fit the MS. This will take at least 4-5 fittings. Remember measure twice cut once WS is high$$$. OK WS fits MS now mark to be able to cut for fit of top and side frames. Next we mark and drill the PILOT holes in the top and sides. Then drill oversize and camphor the holes. Temporally put WS back in and check for fit must fit in WS tight. Success it fits now you can take everything apart to allow you to drill larger holes and install threaded inserts/Rivnuts into the BC for the #6 screws that attaches the MS. Install 2 sided tape to the MS and install the WS then remove 1 screw at a time to allow you to pull off backing of 2 sided tape. NOW we can fit the SKYLIGHT at the top and install screws on side post and top.
If you are lucky this only takes 3-4 days and you don't need to order a new windshield or drilling a hole in the wrong place from being stooopid.

"Looks awesome! Do you buy everything in a kit form, or just figure out which pieces will fit and buy them separately?

Then once it's all done, how do you test it before flying? Know what I mean? Like how do you know it's airworthy without risking a crash?"

Kevin,
This EX-3 Carbon Cub comes in a kit with MOST all parts to assemble. BUT you still have to fabric cover and paint all of the parts. Another BIG PITA but Trey and I enjoy doing it when stuff goes right Sometimes the impossible just takes a little longer and to show the non believers it can be done.

The flight testing begins after you get your two size extra large big balls on. Climb in fire that baby up and see if it will fly.

Really most of the similar homebuilts have flown in the past and will fly you just don't know how well. You and others spend quite a bit of time looking at all of the important parts. If the engine keeps making loud noise most of the time all goes well.


This is what happened to my neighbors DR-1 Tri-Plane. This was on the first flight and due to engine failure and the pilot, not the neighbor, having his head where the sun don't shine. A real shame6 years or so down the crapper and $150K+- along with it. It was also an outstanding build

"

 

[Wyandot Jim]

Looks pretty darn good, Jim. I am really airplane stupid, but is that a 4 cylinder engine w/4 valves per cylinder or an 8 cylinder? I also second Kevin's question, who flies it first? How do you know it is 100%?

Turd,
It is a 4 cylinder and fuel injected with 2 valves per cyl. which makes about 200HP on 360 CI

Trey will fly this one first. The other EX-2 Carbon Cub we did Chad flew it First. I flew my Starduster Too on it's first flight in 1973.

Chad and first flight 2019

 

[Ride1949]

Very nice, and thanks for the info on the engine and the excellent description on the WS installation. You guys have my utmost respect for the work you do.

 

[Kevin]

Yes, thanks for the explanation. I bet that’s a shock when you first get all the parts and have to unpack them.

 

[Wyandot Jim]

Yes, thanks for the explanation. I bet that’s a shock when you first get all the parts and have to unpack them.

Looks like this. Yep got a few parts together. On my Starduster Too since it was built from a set of plans. I had to make all of the parts from raw material.

 

[nekvermont]

That's quite a project and accomplishment. You make me feel like an underachiever.

 

[Wyandot Jim]

That's quite a project and accomplishment. You make me feel like an underachiever.

NAAAAAAAAAAA How do you eat an Elephant??? One bite at a time

 

[Hvymax]

I've always wanted to fly and I knew I would have to build anything I could afford like everything else I have. So far I've been sidetracked with cars, trucks, bikes, guns and boats. All 40 years worth still less than 1 plane. I've seen hovercraft with wings that can cruise 20' or so off the ground. I might have to settle for that.

 

[WendyZXZ]

Very nice, that is coming along beautifully!

 

[Dave P.]

So basically a good deal of care and patience, don't skip the double checks and the POS windshield almost installs itself.
Remember, you're spending quality time with your family.
Look at the bright side, at least you don't have to heat mold it from a flat sheet.
I think I'd take fiddling with the windshield over the paint work any day.
Here's to a completely boring first flight.
Looking good, is it sold yet?

 

[turd]

Excuse my innocence, but why the two exhaust ports per cylinder?

 

[Dave P.]

Excuse my innocence, but why the two exhaust ports per cylinder?

Just the camera angle, intake manifolds are on the bottom of the jugs also.

 

[turd]

Just the camera angle, intake manifolds are on the bottom of the jugs also.

Ah, that solves the question. Thank you. My complete unknowledge of anything to do with aeronautics is showing,,,,,

 

[Wyandot Jim]

Dang that looks nice.
I assume it is an EX? How man hours do ya'll have in it so far?

jimbo,
Sorry I didn't answer sooner. The factory says 1000 hours to complete one. We don't keep track but I'm sure it takes us longer. We must work slower than the rest of the builders.
I didn't keep track on my Starduster but the avg. is probably 3500-4000 hours.

Dave,
Son wants to keep and fly this one awhile before it goes on the market. Probably depends on when he gets another project.

 

[g5m]

Very nice!

 

[Dave P.]

Dave,
Son wants to keep and fly this one awhile before it goes on the market. Probably depends on when he gets another project.

I thought maybe you already had another kit coming and were going into production. Have a sign painted on the hanger...


The Triple H
Flying Machine Factory
" We bleed and swear so you don't have to! "

 

[caryc]

Beautiful project. I have a lot of respect for your talents. I really know nothing about aircraft but I will throw in one thing that I found very interesting.

When I worked in an aircraft job shop, the boss had a whole H86 sitting in his back yard, minus the engine. Anyway I was comparing a flap contour that we were making to one on that plane. I found that the wing and tail flaps if that's what you call them were perfectly balanced. They had a small counter weight on the other side of the hinge so that if you pushed the flap up or down, it would always go right back to aligning with the wing. Cool stuff.

 

[Wyandot Jim]

Cary,
Quite a few planes will have the tail flap(elevator) and ailerons balanced like you describe. This allows for less stick pressure (along with other stuff) required by the pilot. The balance is done by having the weight forward of the hinge point/pins. It also helps eliminate flutter of the controls which can destroy the plane. In the 60s I was at a fly-in and saw a guy killed in a homebuilt due to aileron flutter which tore off the aileron and caused the plane to crash.
Early P-38s had a elevator buffet problems because of this. This kept them form diving at high speeds and allowed the enemy to escape. Later models had a dive flap added and a larger balance weight as you described added. With these modifications a lot of Germans got surprised in a dive when the 38 caught them.

 

[caryc]

Cary,
Quite a few planes will have the tail flap(elevator) and ailerons balanced like you describe. This allows for less stick pressure (along with other stuff) required by the pilot. The balance is done by having the weight forward of the hinge point/pins. It also helps eliminate flutter of the controls which can destroy the plane. In the 60s I was at a fly-in and saw a guy killed in a homebuilt due to aileron flutter which tore off the aileron and caused the plane to crash.
Early P-38s had a elevator buffet problems because of this. This kept them form diving at high speeds and allowed the enemy to escape. Later models had a dive flap added and a larger balance weight as you described added. With these modifications a lot of Germans got surprised in a dive when the 38 caught them.

Thank you Jim.