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leading edge bends?

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pilot4pay

Joined: 01 Jan 2007
Posts: 171
Location: Louisville, KY

Posted: Tue Jan 06, 2009 8:11 am Post subject: leading edge bends?

Chris, being that you are a scratch builder, I would like your advice on leading edge bending. How did you achieve the proper radius? did you use a cylinder of the same diameter as the radius design spec?

Just asking, as I will need to make an appropriate leading edge bend in my tank skins.

Any others wishing to offer intuition on the topic is welcome.

Thanks!

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_________________
Craig Smith
CH640 builder
SN: 0078

"Just think how stupid the average person is,
and then realize that half of them are even stupider!"
--George Carlin

carlossa52(at)gmail.com
Guest

Posted: Tue Jan 06, 2009 9:40 am Post subject: leading edge bends?

Craig, I am building a 601HD, but the process still applies.



I have used a 2 3/8" OD PVC pipe. The radius on the HD wing is 53 mm.

I attached the pipe to a 2x6 to make sure it would not flex, and used those cargo straps to start the bend.

 After things were in place, I used a 8'x1'x5/8" board (from the hw store, to make shelves) to "squeeze" it.



I'll email a picture off-list, as it is > 1 MB.



Another method involves bagging the skin and applying vacuum from a vacuum cleaner.

 I've seen a video, and it is amazing ! Unfortunately it has been removed from youtube, but you can find postings on the subject on the zenithlist: search for Leading Edge Skin Vacuum Forming.



Good luck



Carlos

 CH601-HD, plans



2009/1/6 pilot4pay <pilot4profit(at)sbcglobal.net (pilot4profit(at)sbcglobal.net)>

[quote] --> Zenith640-List message posted by: "pilot4pay" <pilot4profit(at)sbcglobal.net (pilot4profit(at)sbcglobal.net)>

 

 Chris, being that you are a scratch builder, I would like your advice on leading edge bending. How did you achieve the proper radius? did you use a cylinder of the same diameter as the radius design spec?

 Just asking, as I will need to make an appropriate leading edge bend in my tank skins.

 Any others wishing to offer intuition on the topic is welcome.

 Thanks!

 

 --------

 Craig Smith

 CH640 builder

 SN: 0078[b]

- The Matronics Zenith640-List Email Forum -

Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:

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Christian Tremblay

Joined: 22 Aug 2008
Posts: 25
Location: Montreal

Posted: Tue Jan 06, 2009 12:33 pm Post subject: Re: leading edge bends?

I Craig and Carlos, Happy New Year 2009  



I am not an expert, but what I did and understand on that matter :



1 - From Document Standard Spec of Chris Hans for CH640, CH specifyed to bend with a radius of 3mm for bending 6061-T6 in 0.016, 0.025, 0.032 and 0.040 thickness and a radius of 6mm for bending 0.050 and 0.063 thickness.



2 - The radius is half of a circle diameter.



3- To bend 0.025 or 0.023 of your tank you shoud acheive this with a 3mm radius. 



4 - More thick are the alum sheet, more radius you should have. If radius is to small, "microcrak" are too numerous. Il radius is too high, it could made bends less loose or weak.



5- A rod of 1/8 inch in diameter have a diameter of +- 5-6mm (You can buy those rod in a Home Hardware Store). If you wrap a 0.025 alum sheet around this rod, you will obtain +- 3mm radius. This will be pretty close for 0.025 and 0.032, a little bit loose for 0.016, a bit stiff for 0.040. But all will be in the tolerance values calculated by in the CH. 



For my alu brake, I welded to rod, 1/8 and 1/2 on both side of a plate (see my web site : section Tool).



www.zodiac640.com



See you



Chris

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_________________
Christian Tremblay - Montreal, Qc
A guy who build a CH640 from plan - SN0059
www.zodiac640.com

ch701builder(at)yahoo.com
Guest

Posted: Tue Jan 06, 2009 1:02 pm Post subject: leading edge bends?

All,

I have the MOV file on my computer, but... it is 705MB. It was from the Sonex guys, so maybe check the Sonex web site and see if they have the video.



Keith

CH701 -- scratch

N 38.9940

W 105.1305

Alt. 9,100'

*****************************************************



From: Carlos Sa <carlossa52(at)gmail.com>

To: zenith640-list(at)matronics.com

Sent: Tuesday, January 6, 2009 10:39:50  AM

Subject: Re: leading edge bends?



 Craig, I am building a 601HD, but the process still applies.



I have used a 2 3/8" OD PVC pipe. The radius on the HD wing is 53 mm.

I attached the pipe to a 2x6 to make sure it would not flex, and used those cargo straps to start the bend.

 After things were in place, I used a 8'x1'x5/8" board (from the hw store, to make shelves) to "squeeze" it.



I'll email a picture off-list, as it is > 1 MB.



Another method involves bagging the skin and applying vacuum from a vacuum cleaner.

 I've seen a video, and it is amazing ! Unfortunately it has been removed from youtube, but you can find postings on the subject on the zenithlist: search for Leading Edge Skin Vacuum Forming.



Good luck



Carlos

 CH601-HD, plans



2009/1/6 pilot4pay <pilot4profit(at)sbcglobal.net (pilot4profit(at)sbcglobal.net)>

[quote] --> Zenith640-List message posted by: "pilot4pay" <pilot4profit(at)sbcglobal.net (pilot4profit(at)sbcglobal.net)>

 

 Chris, being that you are a scratch builder, I would like your advice on leading edge bending. How did you achieve the proper radius? did you use a cylinder of the same diameter as the radius design spec?

 Just asking, as I will need to make an appropriate leading edge bend in my tank skins.

 Any others wishing to offer intuition on the topic is welcome.

 Thanks!

 

 --------

 Craig Smith

 CH640 builder

 SN: 0078

[b]

- The Matronics Zenith640-List Email Forum -

Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:

http://www.matronics.com/Navigator?Zenith640-List

carlossa52(at)gmail.com
Guest

Posted: Tue Jan 06, 2009 1:47 pm Post subject: leading edge bends?

One more thing I forgot to mention: the tank can follow the curvature of the wing nose skin - but you can also simplify and make it straight, like the XL tanks...

See bottom half of this page: http://www.zenithair.com/zodiac/xl/design-wings.html

 



Carlos



  [quote][b]

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Ron Lendon

Joined: 10 Jan 2006
Posts: 685
Location: Clinton Twp., MI

Posted: Tue Jan 06, 2009 6:40 pm Post subject: Re: leading edge bends?

 	  pilot4pay wrote: 	
		  Chris, being that you are a scratch builder, I would like your advice on leading edge bending. How did you achieve the proper radius? did you use a cylinder of the same diameter as the radius design spec?

Just asking, as I will need to make an appropriate leading edge bend in my tank skins.

Any others wishing to offer intuition on the topic is welcome.

Thanks! 	




I'm not Chris but you can see the process I used to bend my leading edge skins



Go to mykitlog site, click on the Wings link and search for "Cut and bend LE Skin".  I have eight entries there showing the process I used.  The 58mm stop block is right for the XL leading edge radius.



Just some food for thought,

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_________________
Ron Lendon
WW Corvair with Roy's Garage 5th bearing
CH 601 XLB
N601LT - Flying
http://www.mykitlog.com/rlendon
Corvair Engine Prints:
https://sites.google.com/site/corvairenginedata/

zodierocket(at)hsfx.ca
Guest

Posted: Tue Jan 06, 2009 7:15 pm Post subject: leading edge bends?

http://www.ch601.org/resources/Nose%20Skin/bending_a_nose_skin.htm



Pictures tell the whole story

Mark Townsend  Alma, Ontario

Zodiac CH650 C-GOXL, CH701 Rotax 912,

STOL CH750 Just started

www.ch601.org / www.ch701.com / www.Osprey2.com

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pilot4pay

Joined: 01 Jan 2007
Posts: 171
Location: Louisville, KY

Posted: Wed Jan 07, 2009 6:24 am Post subject: Re: leading edge bends?

I see there are several methods for the process, I guess I need to be more specific in the question.

Carlos used a 2-3/8 pvc pipe, which is 60mm dia. roughly, for a 53mm finished radius(?)(60mm dia = 30mm rad). Please e-mail th pic to me, address is listed on post.

Ron used the flat press method with 58mm stop block, for the same LE radius?

I see the process at 601.org, 58mm stop block for 53mm radius, on the 601.

I don't have my notes in front of me with my template dimension for the tank LE radius, but the trend is a stop block or pipe 5 to 7mm larger than desired radius? I guess that's the little detail I'm looking for. Am I using the terms radius in the correct context, or should we be talking dia.

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Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:

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_________________
Craig Smith
CH640 builder
SN: 0078

"Just think how stupid the average person is,
and then realize that half of them are even stupider!"
--George Carlin

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