R/C Red Hawk Project into F16 Card Model

Discussion in 'Radio Control & Other Propulsion Methods' started by mbauer, Apr 8, 2007.

  1. mbauer

    mbauer Cardstock Model designer

    Joined:
    Feb 1, 2006
    Messages:
    153
    Likes Received:
    23
    A friend at work bought this small 3-channel RC airplane. He has crashed it several times replacing the parts as needed. His last attempt at eating a chain-link fence ended up looking like this! The wings were completely shredded.

    The RC parts survived, the plane can be rebuilt for around $30 USD.

    Red Hawk Specifications:
    Wingspan: 41"(1041mm)
    Length: 28.5" (723.9mm)
    Fly Weight: 16.9oz (479.11gm)

    RC F16 Card Model Specs:
    Wingspan 21" (533.4mm)
    Length: 36" (914.4mm)
    Weight: 15.8oz (447.92gm)
    Range: 500' (152.4m)

    He gave me the parts to adapt them to a card model.

    This thread is about converting foam/plastic to cardstock.

    It will show some of the techniques I've learned/used to create big models that fly!

    Best regards,
    Mike Bauer

    BTW-I'm in the process of moving to a new place (already here just need to get moved in...i.e.;Find my cutting tools!!)

    Attached Files:

  2. mbauer

    mbauer Cardstock Model designer

    Joined:
    Feb 1, 2006
    Messages:
    153
    Likes Received:
    23
    RC Parts and Cardstock Mounting Parts

    My answer to mounting the parts from the Red Hawk.

    Cardstock used is International Paper's Springhill Tag 125#. Equivelant would be Springhill Index 110#.

    The motor itself is mounted just like in the plastic model. 6-pieces of laminated cardstock easily handle the job of mounting the motor using the screws provided by the Red Hawk. Notice the half-moon shape cooling air flow holes. (changed while building from the small holes around the perimeter).

    Inside there is an additional lamination of 4-pieces of cardstock around the motor. This stabilizes the motor and makes the tailcone extremely strong!

    Battery tray will have one wrap of 1" (25.4mm) wide cardstock glued solid.

    Servos are mounted on the plastic frame supplied by the Red Hawk. More photos later of control line(pushrods=fishing line) from servos to Elevons.

    Attached Files:

  3. mbauer

    mbauer Cardstock Model designer

    Joined:
    Feb 1, 2006
    Messages:
    153
    Likes Received:
    23
    RC Parts and Cardstock Mounting Parts

    Servos are mounted on the plastic frame supplied by the Red Hawk. More photos later of control line(pushrods=fishing line) from servos to Elevons.

    Notice fuselage piece under everything!

    Attached Files:

  4. mbauer

    mbauer Cardstock Model designer

    Joined:
    Feb 1, 2006
    Messages:
    153
    Likes Received:
    23
    How to Make Really Strong Wing Spars

    Notice "Fanfold" wingspar? Next Photos show these in action!

    Bag of goodies, soon to be used! More parts supplied by Red Hawk!

    Attached Files:

  5. mbauer

    mbauer Cardstock Model designer

    Joined:
    Feb 1, 2006
    Messages:
    153
    Likes Received:
    23
    Basic Wing Construction

    Wing construction using ribs/spars.

    Double ribs allow tabs on both sides to help glue wing skin to rib equally (helps stop warping)

    Attached Files:

  6. mbauer

    mbauer Cardstock Model designer

    Joined:
    Feb 1, 2006
    Messages:
    153
    Likes Received:
    23
    Keep Wing Skin Tight to Frame

    When gluing skin to internal structure, start at tip and then work towards wing root! Must keep strecthing the skin tight to trailing edge, while gluing!

    Attached Files:

  7. mbauer

    mbauer Cardstock Model designer

    Joined:
    Feb 1, 2006
    Messages:
    153
    Likes Received:
    23
    Wings Done!

    Wings Ready to Mount to Fuselage!

    Elevons are also done! Elevons are made from 6-total laminates of 125# cardstock. The center 2 laminates are the only ones that are complete. The other laminates are cut where the actual control surface is needed. You can see this on the left Elevon. The center laminates are used as the hinge! THe final laminates actually cover the rest and give it the airfoil shape.

    Attached Files:

  8. mbauer

    mbauer Cardstock Model designer

    Joined:
    Feb 1, 2006
    Messages:
    153
    Likes Received:
    23
    Fuselage is Next!

    Rolling/Gluing the fuselage.

    I use the chair and table top as "bridge" foundation for some wood dowel. On the dowel are wraps (bands) of double stick tape placed about 3" (75mm) intervals. This holds the fuselage for gluing and yet allows it to "pop" right off when done.

    One wrapping session will last many, many models!

    Outside fuselage skin is done, internal section is being glued! Lines on internal section are for the internal formers (bulkheads). Wingspars will penetrate thru both walls of fuselage. Lots of glue points = strong model!!!

    Attached Files:

  9. mbauer

    mbauer Cardstock Model designer

    Joined:
    Feb 1, 2006
    Messages:
    153
    Likes Received:
    23
    Photo of Internal Fuselage

    Photo of Inside View of Fuselage:
    -Double wall fuselage design
    -Wingspars
    -Rudder Support (vertical cardstock in rear of photo-hazy looking)

    Attached Files:

  10. paul a

    paul a Member

    Joined:
    Mar 22, 2007
    Messages:
    323
    Likes Received:
    0
    got to love it another RC card model. it looks great excellent job!
  11. mbauer

    mbauer Cardstock Model designer

    Joined:
    Feb 1, 2006
    Messages:
    153
    Likes Received:
    23
    Fuselage Ready for Wings Final Assembley!

    Fuselage ready for mounting of wings. Notice spar holes have been cut, they go thru both skin and internal fuselage pieces. Biggest opening is to allow gluing of the internal fuselage former.

    Rudder internal support system is installed!

    Notice how the motor attachment system fits nice and snug? Slides on and off, using velcro to hold in place during flight!

    Attached Files:

  12. mbauer

    mbauer Cardstock Model designer

    Joined:
    Feb 1, 2006
    Messages:
    153
    Likes Received:
    23
    Gluing Wings to Fuselage!

    Starting to align and insert the glue tabs.

    Once inserted for test fit, slide slightly out and glue each side of the spars. Slide in and then hold while spars set. MAKING SURE TO KEEP THE WING LEVEL! as the glue sets.

    Once the spars are in the next step is to glue the tabs.

    Once both wings have been attached, the final step is to glue the wingspars from the right and left wings together. (harder than it sounds). Had to make a special tool to reach inside and use as a back-up while applying pressure with a wood dowel!

    Attached Files:

  13. mbauer

    mbauer Cardstock Model designer

    Joined:
    Feb 1, 2006
    Messages:
    153
    Likes Received:
    23
    Attaching the Side Rails/Elevons

    Next is gluing side rail to fuselage.

    Once this is done the Elevons are mounted to the side rail and also to the fuselage as well.

    Attached Files:

  14. mbauer

    mbauer Cardstock Model designer

    Joined:
    Feb 1, 2006
    Messages:
    153
    Likes Received:
    23
    Almost complete! Move has intruded on construction!

    Model Completed to this point. Moving to a larger apartment has interuppted the construction. Can't find anything!!! Better packing the next time!!

    Still need to:
    -Glue in Servo tray/Hook up control "rods" to Elevon/Servos
    -Finish removable nosecone
    -Weight balance (determine battery tray location)
    -Wire the motor to the battery
    -Charge the thing up and go fly it!

    Attached Files:

  15. mbauer

    mbauer Cardstock Model designer

    Joined:
    Feb 1, 2006
    Messages:
    153
    Likes Received:
    23
    Weight of Model and Parts (Estimate of Flight Ready Weight)

    All of the parts on the scale plus the trim and an allowance for the glue (extra cardstock added to the pile).

    Looks like the card model is 1 ounce (28gm) less than the store bought foam so far.

    Hopefully it will be up and flying by next weekend! Have to go thru some more boxes to find all of the stuff!

    Mike Bauer

    Attached Files:

  16. paul a

    paul a Member

    Joined:
    Mar 22, 2007
    Messages:
    323
    Likes Received:
    0
    hope you find all the parts again would love to see it fly.As I said befor great job.
  17. mbauer

    mbauer Cardstock Model designer

    Joined:
    Feb 1, 2006
    Messages:
    153
    Likes Received:
    23
    Thanks for the kind words!

    Best regards,
    Mike
  18. mbauer

    mbauer Cardstock Model designer

    Joined:
    Feb 1, 2006
    Messages:
    153
    Likes Received:
    23
    Paper Work is Done!

    Removable Nosecone is Done. Just need to wire, weight and balance, mount the servo and battery, hookup control and charge the system up!

    Should be done for a Saturday Test Flight!

    Attached Files:

  19. mbauer

    mbauer Cardstock Model designer

    Joined:
    Feb 1, 2006
    Messages:
    153
    Likes Received:
    23
    Prototype RC Alpha Build

    Prototype Alpha Build

    Sure can see how bad my skills are. Usually I would hide the junction with a thin piece of paper as trim down both sides (top & bottom). Instead I ran a bead of glue trying to save weight.

    15.8 oz with battery and radio/servo trays total weight. Add at least 0.2 for wiring and the model still is less than the original model!

    Attached Files:

  20. John Griffin

    John Griffin Member

    Joined:
    Sep 30, 2005
    Messages:
    175
    Likes Received:
    0
    Awesome!

    Looks really nice! Did you design it from scratch or use a kit as a basis? (Sorry if this was covered in the thread and I just missed it).

    Have you thought about lightweight landing gear? That node seems apt to catch in the ground/lawn/ or whatever you set down on.