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Author Topic: 1/4 Scale Ka-1  (Read 59424 times)

Fred

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« on: January 05, 2009, 08:26:43 AM »
Well, after a very long break in building vintage gliders (wayyy too long !), a box arrived home, full of wood !
Enough to put a smaile on my face on one of the most depressing day of the year !

This time, I'm going backward and build a Kaiser Ka-1. The Ka3 come from this model, the Ka-1 being all wooden construction (Ka3 is tube and fabric)... Everything else are common to the 2 machines (wings and tail) which help a lot in the designing process !  :D

Starting with the fuselage, this one is built in 2 halves... Not sure if that's a good choice compared to a build using a jig, but will see !

The basic frame is made of 2mm plywood



Formers are then glued to the frame







We add the 5x5 sq. hardwood strips. Note that everything is built inside the fuselage. the servo tray, cockpit floor etc etc are glued in each halves of the fuselage.



The fuselage is then removed from the table. I've put water on the wood strips, and put back the fuselage on a flat surface with loads of weight to have it really straight before going further.

A last view of the fuselage


Start to look like something !
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Happy Days

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« Reply #1 on: January 05, 2009, 12:27:57 PM »
What type of glue do you use with the plywood Fred?...and why? :?:

K.
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Fred

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« Reply #2 on: January 05, 2009, 12:37:37 PM »
Hi Keith,

I use my usual mix of white glue and Cyano.
Because you have the best of both world  :D  
Strenght with the white glue, fast with the CA.

And I have just received this morning my Bottle of Gorilla Glue (PU)  :D  I'll build the wing with that one. You can't use CA with it and need 2 hours to cure, but with the wings, you don't need to hold all the parts together, so that should be perfect ! Worth a try, I will let you know !  :D
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Alan_Perse

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« Reply #3 on: January 05, 2009, 13:38:20 PM »
Looks Great Fred  :D :D . When do you think you will have it ready? What kind of colour scheme have you planed?
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Fred

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« Reply #4 on: January 05, 2009, 13:43:00 PM »
Thanks Alan,

Hopefully by the end of the month.. But going slowly on that one, The fuselage planking is going to be the major bit :D
Finishing will be all plywood + varnish.
No paint as I am absolutely useless with paint (a bit like if you leave a 4 year old re-painting your house...  :?:  Well, saying that, he may do a better job than mine ! )
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Fred

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« Reply #5 on: January 06, 2009, 08:12:14 AM »
While the fuselage half is still drying (-2 degrees in the garage yesterday !...) I had a look at the wing and started building them, until my fingers freeze !  :roll:

A bit of the pieces... Lots of parts!



Then, classical work, gluing the ribs on the lower spar, keeping everything as straight as possible...



During progress on the build, incorporate the servo frames for the ailerons and airbrakes... Everything slots together, so no real big deal here...





Then, it's time to close the ailerons...



And that's it ! Too cold in the workshop, I'll continue tonight.
Left to do are the Upper spar, webbing, TE, LE and tips.. Enough to keep me out of drugs !  :P
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Alan_Perse

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« Reply #6 on: January 06, 2009, 14:07:03 PM »
Goes together quick. Will you be making it avalable as a short kit?
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Fred

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« Reply #7 on: January 06, 2009, 14:29:45 PM »
Thanks to the cnc cutting !
As usual, a non event to assemble the thing !

We'll see after the build, if successfull, that will be added to our range  :D
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Fred

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« Reply #8 on: January 06, 2009, 23:38:46 PM »
Alright, let's get some progress !

I have continued with the wing, and glued the upper spar in place, so as the fake LE and the TE...
A bit of bad names with the TE, as you need something like 3 hands to put it in place!   :P  But with a bit of patience, finally done it after 10 minutes...



The wing root is also made. The angle of the first rib is 2 degrees for the diedhral. And a triangular piece gives the right angle to the front rib.



And the fake LE



Then, I focused on the wing tip.

Really easy, all the pieces are interlocking with each other !
First the ribs



Then the tip frame in 2mm plywood



And finally, all glued with epoxy to the wing. I also added 2 small pieces of reinforcement, but that is not really necessary, just for peace of mind...



And that's it !
Left is the aileron to complete, the webbing and sheeting, and the piece de resistance, the Airbrakes mounting brakets and so on !

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Fred

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« Reply #9 on: January 06, 2009, 23:48:34 PM »
Back to the fuselage for a little while.
I have glued the front skid support so as the cabin floor, all in 3mm plywood.









After that, to have a break, I built the pilot seat. I have shamely (?) stolen the design from Vincent's MG9a !  :oops:  Thanks Vincent !  :D

The parts (3mm plywood)



And 2 minutes later :



The seat will be covered with 0.4mm plywood as soon as I start the fuselage sheeting...

And in the cockpit, just to have a look  :D



And that's it for tonight !

Tomorrow, my plan is to start the second half of the fuselage, and start the airbrake assembly in the wing.

Stay tuned !  :D
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Fred

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« Reply #10 on: January 07, 2009, 21:47:57 PM »
Not much done this evening... Wayyyy too cold in the garage ! (still -2...)

Anyway, managed to start the other half of the fuselage...
And here is a trick that can be usefull...
How to get the other side of the fuselage on the paper plan ?
An old trick is to use kitchen oil, that you spray (just a small amount !!) over the "side B" of the plan.



And the result (look much more sharp in real...)



Of course, work for wings, tail etc etc...  :D

And the fuselage...



Tomorrow, I should start the airbrakes... If I don't get the flu before ! :P
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« Reply #11 on: January 07, 2009, 22:12:48 PM »
I'd buy you a garage heater for next christmas Fred, but you haven't got any room for one!  :roll:
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Fred

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« Reply #12 on: January 08, 2009, 08:54:35 AM »
Actually.. I was looking for a Gas heater earlier this year...
But I need to properly seal the garage door, that's mostly where the cold come from !
Garage should be empty for spring cleaning in 2 weeks time, and I have 120m2 of Depron hanging around...
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Fred

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« Reply #13 on: January 09, 2009, 09:17:46 AM »
Yesterday evening, I finally assembled the 2 fuselage haves.
Took some time, as you have to move slowly to make sure that everything is straight !

Start to look like a glider now !  :D







A few pieces are added to finish to link the 2 halves...



And you can add a few more if you want, like under the cockpit floor and so on to add some strenght.

Here is a view of the front skid... This will be later closed with a strip of 3mm plywood before starting the fuselage sheeting...



And that's it for today !

Rain forecasted this week end... Sound like some "good" days ahead to spend time in the workshop !
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Fred

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« Reply #14 on: January 21, 2009, 15:13:38 PM »
Ok, after a week off the workshop, preparing the new family addition that is coming really soon  :D

During the week, I managed to work a little anyway, and here is what I've done.

The V tail support as been glued in place on the tail. Just missing are the carbon tubes for the joiner.

Here are the parts :



And all glued together :



Then, I started with the V Tail...



And after 15 minutes of hard work in the sitting room (not crazy for once ! Worked in a warm environment ! :P  )



Left to be glued are the blocks where the hinges are going.
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