Here are some pictures of all the parts for the Spline :
This is the mould for the v-tail-linkage , just before demoulding the first part.
Mould is open...
Here you clearly can see the hole in the middle, were we injected epoxy trough with a syrenge, to totally fill up the parts.
Finished parts, the one testmounted with a ball for the linkage.
But we are not totally satisfayed, so we will make some more samples in different techniques.
We have found out that a carbon sleeve is giving better torsion, than the rovings, so today we only make the V-tail linkages of carbon sleeve.
The mould for the V-joiners, just before demoulding..
Finished parts, and we are satisfied with the quality, so we start massproduction of these parts....
John has found a way that we are going to make our linkages for the Aileron and Flaps, with flush linkage.
The parts are made using a 1,56mm ejectorpin, with carbonfibre wrapped around and pressed between to plates.
These we are going to glue in the wing before closing the moulds, and we are going to cut away the sanwichmaterial away were these are placed in the rudders, so they will be fixed between the inner and outer skin.
RDS is much to comlicated for us...:-)
We have made a test for the pocket for the v-tails during the night, and it fits exactly.... These pockets we make of kevlar sleeve now.
John is starting on building the first wing joiner in the mould.
John "Wie immer in unterhosen"...... it is hot in Denmark today, good for epoxyhardening...
Unidirectional Carbon for the joiner.
Jan is sanding the positive for the fuselage before polishing.
Some of the parts waiting for next time waxing.
Wing joiner mould just before opening.
First joiner for the Spline. Weight 89 grams.
John has tested its strenght , he turned it upside down on the floor and stepped on it in the middle (John = 110kg...) and it flexed 0,9mm in the middle.
End view of the joiner. Today we make the cores of rohacell, and the vertical ribs of carbon, and we also have a big carbon sleeve all around.
Louise , Jans wife is helping the Spline team with preparing rovings for V-tail joiners.
4 pcs. V-tail joiners and 1 set of linkages for the V-tail in the moulds.
Notice the syringe in the linkage mould, it fills the remaining air in the cavity with epoxy.
The first V-tail
2 layers of 25g glasfiber and 0,50 mm balsa and 1 layer of 25g glasfiber
UMS carbon for the spar
It looks okay !
The weight is 40g without the joiner
I think we can make it a few grams lighter, with less carbon in the spar, it is VERY strong ....
Stock is building up on small parts.....
We have made a steelplate for milling the servoplates, it can make 11 servoplates out of 1 plate.
Here the steelplate is ready with all the treadholes and clearance for the mill.
Here the homemade Glass/Carbon plate is mounted on the steelplate with 6x M6 screws.
Now the Matsuura makes all the holes for servos , contact and M3 threads.
Then 3 screws per servoplate is placed, 1 in the hole for the contact and 2 on the edge of the holes for the servos, and the first 6 screws holding the plate is removed.
Then the outer contour of each servoplate is milled, and all the 88 x M3 treads are also cut in the machine.
and then we have 11 finished servoplates, only need to be sanded a little, and no "connecting bridges" are needed!
And sanded and ready to be used.
The cores for making the pockets for the wings are also ready now.
Surface grinded on 4 sides , and the R2,5 is milled on each corner.
Yes, the first "real" Spline Fuselage out of the mould...., (we have made a test in glasfibre first)
Weight is 250gr. and it is strong. :-)
The rear part with the cover mounted.
And from the bottom.
And without the cover.
The wing root, there are some airtraps arond the holes, but we think it is air that comes in around the cores when we have the halfes in vacuum, so we need to do the cores more airtight during the vacuum.
The front with the servoplate (not glued)
The V-tail fits exactly on the fuse, the end of the rudder is lying very tight to the fuselage without touching it. (this picture is of the first glassfibre testfuselage with the test v-tail)
Same viewed from the bottom.
The tube for the joiner, 1 layer of glasfiber and kevlar rovings
The V tail, 1 layer of glas 54g/m and 1 mm rohacell 52
The inner layer 54 glas and UHM carbon for the spar
Nice with small moulds, fits on the table
Carbonsock on straws
The weight is 40 grams per piece, but we hope to get close to 35 g
We try to build the V thail lighter !!!
4)More hard woork :-(
First paint, then one layer of 54 g glassfiber,
1 mm rohacell 52,
Next day :
Trim all the edges
make grooves for the rudder
inner layer Disser tissue 38g glas with carbon
Be careful with the epoxy
It looks good the tissues
we have also moved the peel pla to the inside. It was earlier located between the outer tissue and the rohacell, now it is on the inner side between the rohacell and the inner tissue.
It is much faster and is not visible on the surface anymore.
The front bar has 2 layers of 1.5 mm balsa with fiberglass in between and on the side.
It is glued in with a carbon fiber roving nf 24, so it must fit quite well in the height.
The middle distance piece is Rohacell 71 which are glued into each half and cut down in height to suit.
The rear spacing is a piece of straw with carbon fiber sock around
The V-tail-linkage are glued in with epoxy and cotton
waiting is hard.......
After rudder is cut out
The rudder is stiff, and best of all is the V-tail is now 14g lighter
so the weight is 33g per half.
and maybe just save a few grams more ........
Jan has made some smallparts for the Spline :
Pockets for the wings, 12 gr. each . Note the glasfiberrovings in the one end, these are for getting the pockets of the cores. That makes it much easier to get them off!
Pockets for the V-tail, also with 1 glasroving tied around to make it easier to get of the steelcore.
V-tail joiners , 6 gr. each
Tubes for the Ballast, these are made on a 12,2mm Ejectorpin, that means that a 12mm Tungsten carbide mill fits easily inside...
We have started to collect old used Ø12m full Tungsten carbide mills, to use as ballast. We cut of the part with the cutting edges with a special diamond coated thin grinding disc.
Each ballast will be Ø12 x 55mm long, with a weight of 100 gr.
Each ballast tube is 275mm long , and there will be 2 in front and 2 in the back of the joiner, so we will be able to put in 2000gr. of ballast in total..... should be enough...
We have got some stickers made for masking of the moulds when painting the Spline logos. 2 types , one with the letters remaining , and one with the "non-letters" remaining, because on the top of the wing, the logo is red on white background and on the bottom of the wing the logo is white on red background.
One of our smaller Spline team members is just checking the stickers....
As you can see , he has his fresh air supply on, he use this when he helps us joining the fuselage from inside the mould.....:-)
John has painted the moulds, this shows the upper an underside before painting with white.
Jan made a test assembly of the RDS system, to be sure about the right location of the pockets.
We use the RDS frames from www.formenzauber.de , they makes it really easy to build in RDS , I would call it "RDS for everyone" , they come with the angle pin also , just tell Sven Hollenbeck what angle you need , and he makes them for you.
The RDS pockets we made on a steel core, and it is made of 1 glass sleeve , and 1 layer carbonrovings around, and then pressed between 2 plates, to make it as low as possible. Then it is cut in 10mm slices, and the one end is closed with some balsa, to ensure that there comes no epoxy inside wenn gluing the pockets in the wing.
The harness for the wing is ready for gluing in the wings. We use 0,5mm cupperwire with Lacquer , instead of normal wires, to save weight.
Were the + and - goes down to the Flapservo , we just soldered the wires together, (remember to sand of the Lacquer), and put over some shrink tubing.
To the left the tungsten carbide ballast, they are Ø12x55mm and weight is 90 gram each. To the right some Ø12/Ø10 aluminium tubes for spacing the ballast.
Jan is gluing in the servoframes and the rds pockets.
Cutting slots in the balsa webbing for the wires.
The Cupperwires are installed
Soldering the wires to the connector
Carbon sleeves on straws , for the rudders
We glue in the connector in the wing from the inside before we close the mould.
We fix the connector with some 5 min. epoxy first
The fuselage with connector
Servoes in the fuselage.
We have made some templates for gluing the Servoes with the Formenzauber frames in the wing.
There is also a cutout for placing of the RDS pocket.
Same for the Flapservo. The plates are guided on to of the centering pins in the mould.
John has also made some templates for gluing the spar in front of the hingeline. These are also centered on the centering pins in the mould.
And John also has made a template for cutting the hingelines on the v-tail.
The new templates in action...
And here the pocket is glued in the right place.....
Jan in action with the RDS pockets.
Wires in place......
Building of a Spline fuselage with ballon inside :
Template for cutting out the kevlar pieces.
Jan is cutting with his new rollercutter on the new cutting plate.
We paint the innercone at the same time as we paint the outercone moulds.
We have done some covers for painting for quick and easy painting job. Picture of these covers will follow, as we left them for now at the paintshop.
These pictures show a little trick to get a cord connected to the closed end of the balloon. We use the Sempertex 660 balloons. The little yellow thing is a "Hama" pearl from daughter Andreas room...
We put the pearl down in the balloon, and make a self tightening knot around the pearl.
In the other end of the balloon, we place a tube with a Festo connector screwed in.
The tube is put into the balloon, and a rubberband is tightened around the balloon.
Jan is cutting excess material of with the toothed scissors. John is taking pictures.
The ballon is now fastened to a screw in the backend of the mould.
The balloon is then stretched out, and the the tube placed in the retainerplate at the front of the mould. We "grease" the balloon with some "Vaseline" creme (dont know if thats only a danish name?) , to get the balloon to easier come out of the finished fuselage.
When the balloon is placed, we hold down the excess material with some thin sewing cords. On the side of the mould we have put in some screws for holding the cords.
When all the mould is coveres with the cords, the other mouldhalf is placed on top.
Be aware not to cross the guide pin holes with the cords..
A look into the V-tail end of the mould.
When the mould is almost closed, we cut the cords, and pull them out again.
Jan is pumping up the balloon with a bicycle pump. At the opening at the V-tail we put in an "dummy" mouldpart for giving the balloon something to be stopped by, otherwise it will just expand out of the hole an explode.
We blow the balloon to 1,4 Bar pressure. We tried higher but sometimes with bad luck in the balloon.... so we keep it at 1,4 bar. And there is coming a lot of excess epoxy out of the mould still. The first 10-15 minutes we place some 0,3 steelplates between the mouldhalfes to give a little gap for the epoxy to come out of, before we tighten the mould completely.
Here the epoxy comes out.
And at the bottom, John catched a drop in the air with the camera.
More to follow later....