Bigfoot #2 rebuild

[Kevin Rochon]

Ok here we go again, it's going to be a bit of déjà vue...hey I could use the old pics and you'd be none the wiser;)

First I installed a small screw on my Futaba's slider(as per suggested by Andrew) so it is easier to reach, useful for the Bigfoots and the Harvard flaps.

So I just laid out the motor box kit and looked at my old rebuild to get familiar with it. I had traced the cockpit former and the side balsa that's going to speed up the process. First thing will have to make and install the balsa doubler on the floor.

[Kevin Rochon]

Just a little bit of work tonight. Cut and glued the 1/16" balsa doubler for the floor. Got a use for those dumbbells;)

[Kevin Rochon]

A little more work tonight. Did the cutouts on the balsa floor doubler.

[Kevin Rochon]

Started gluing the cracks in the fuselage. Added a splice behind the door frame to reinforce where the crack is.

[Kevin Rochon]

It's a good day to be in the work shop.

So I gathered the puzzle pieces, what was left from both sides and I was able to trace it on the new 1/16" plywood. I will have to do 2 of them not quite the same, the one for the door side is smaller of course.

It doesn't look like much but it's a big step in the repair process since I have the new formers and floor kit.

[Kevin Rochon]

So let's proceed with this one.

Cut out the LH side frame just put it in position so you can understand. Now I have to make the RH one which is quite similar. But these take time to cut out, band saw, drill press, scroll saw and chisels, but I enjoy it.

[Kevin Rochon]

Made the RH side tonight, takes a lot of adjustments to get the former to fit into the different slots.

[Sempai-mj]

The block on the bottom is for the landing gear?

[Kevin Rochon]

Yes Michael, it's a channel and it has the 3 blind nuts glued to it(you can't see it, it's on the other side)

[Kevin Rochon]

Tonight I adjusted, as best as possible, the 2 sides to where they will have to be spliced to the fuselage. Had to do a dry run trying to make it as straight as possible, but probably more adjustment will be needed.

[bob forest]

Kevin, that is real nice work. I think you really enjoy doing repairs. Is that why you keep on crashing. just joking. Nice work.

[beto9]

Kevin, that is real nice work. I think you really enjoy doing repairs. Is that why you keep on crashing. just joking. Nice work.

It has been a long held suspicion at WIMAC!

[Kevin Rochon]

Actually I hate repairs, but it has to be done. I take it as practicing building;)

[Sempai-mj]

After a crash it's a challenge and a sastisfaction to get it to fly again .

[Kevin Rochon]

Tonight a lot of work but not a lot of progress:rolleyes: I made the last 2 parts I needed, one is the dash with the bottom part and the other the part that goes from the dash to the top, it is behind the windshield.

I will have to redo the dash as I had traced it when fixing the 1st Bigfoot but I should of measured before cutting(measure twice cut once) it was too wide at the bottom, it has to be a little in V shape & I put the bump for the door lock at the bottom instead of the top.:confused::confused:

[Kevin Rochon]

Well good day again to be in the workshop, or dinning room hey Billy;).

Re did the 2 parts I did the other night. Had to redraw 3 times a lot of filling and sanding and figuring out, good thing I have the other Bigfoot.

Still have to do the cut out or lightning holes but all fits ok and is properly aligned and as straight as possible.

[mdauth]

So did you decide on the power system yet??? Looking good.

[Kevin Rochon]

So did you decide on the power system yet??? Looking good.


Merci Michel,

not sure what I'm going to do with it yet. Electric, Gas or sell it or keep it as a backup:D

[Kevin Rochon]

So the 2 parts are done, did the holes and slots. Now just have to make some sticks that reinforces the top and bottom at the corners then start gluing. You can see what I had left to try to make the new parts:rolleyes:

[Tarek Hassoune]

good job Kevin you are the master of repairs

[Kevin Rochon]

Well today got up and wasn't feeling too well(headache and tiered) So I missed, I'm sure a perfect flying day:(

All I did was cleanup the workshop and made the sticks for the corner reinforcement and 2 doublers for the carbon rods. I also figured the sequence of gluing.

[Sempai-mj]

Well today got up and wasn't feeling too well(headache and tiered) So I missed, I'm sure a perfect flying day:(

All I did was cleanup the workshop and made the sticks for the corner reinforcement and 2 doublers for the carbon rods. I also figured the sequence of gluing.

Was too windy today, it was a repair day, i redid the tubing on my beaver, it won't start. :mad:
Tank is higher than the dle 35ra

[Kevin Rochon]

Too windy weren't they showing 15k NW?

Michael it doesn't matter where the tank is it's gas so the carb got a pump, must be something else?

1st is fuel getting to the carb (check plug for flooding though)
2nd is there a spark
3rd if yes to 1 & 2 it has to start

[zorba]

And don't forget you have to spin the prop:D

[Sempai-mj]

And don't forget you have to spin the prop:D

My arm felt the prop spinning!

Spark is there and there's flooding, I'll remove the cowl and see if the fuel is flowing.
Thanks

[briankizner]

I find that , for the first start of the season, my DLE 55 tends to be difficult, much like my old lawnmower was. The cause is apparently old fuel solidifying in the fuel lines blocking the flow of gas. The solution is to remove the plug and spray engine starting spray (ether) or a few drops of gasoline directly into the cylinder. This will help the engine fire up. The suction in the lines caused by the engine firing easily clears the blockage and the motor is then fine for the rest of the season.

[Sempai-mj]

Thanks for the info, ok Kevin back to your thread.

[Kevin Rochon]

Now like Michael said back to work.

Today I received my Falcon props, 2 x 20x10(AJSlick) and 2 x 22x 8(Bigfoot) and some EC5 connectors.

Tonight I glued the floor to the different formers.

[Kevin Rochon]

Tonight I tested how much I could glue without having to put the piece into the fuse. The only part I need to glue when inside the fuse is the top part that is behind the windshield and goes in the top cabin, I need some adjustment when in the fuse before gluing so I glued the bottom of the formers and the landing gear carbon channel and the engine box. I would of glued the side and the dash but not enough clamps(on my shopping list;)).

[zorba]

No wonder I can't find any, you got them all;)
Great job Kevin.

[Kevin Rochon]

Some more gluing. The only thing not glued here is the top part so when I put it in the fuse I can adjust it.

[Kevin Rochon]

Tonight joined the box to the fuse. Went pretty good I did a dry run first to figure out where to put all the clamps and make sure all aligned. I had to make a wire hook for the inside so the floor was tight with the back former.

Still a lot to do. Reinforce the side joints then do the balsa stringers for the bottom then the balsa sheeting for the side and bottom and top deck and balsa channel, then covering....ouf:rolleyes:

[Sempai-mj]

Starting to look like a foot again, great job!

[Kevin Rochon]

Thanks Michael.

BTW I saw that 3DHS is coming out with a "Little foot" it has 53" wingspan.

Tonight, since I was balancing my new props(beside mowing the lawn, cleaning the pool...well the robot did it, did the laundry) so I just removed all the clamps.

[Kevin Rochon]

As promised I did some more work on the Bigfoot, winds being a bit strong and crossed:O_o:.

I put a balsa triangle in between the dash and the top ply to reinforced the joint. I installed some hardwood reinforcement where the new ply meets the old. I also put some doublers on the back end of the landing gear plate, with minimal weight a lot of strength is added. I installed the balsa sheet channel as it is much easier now.

[zorba]

How much weight are you adding to it Kevin? you might need those bar bells again;)

[Sempai-mj]

How much weight are you adding to it Kevin? you might need those bar bells again;)

Looks very little, no need to Rename the plane to lead foot.:D

[Kevin Rochon]

We're taking grams here Billy;)

[Kevin Rochon]

Tonight I made the 1/8"+/- stringers and installed them, looks simple but a lot of adjustment and, yes Dan, some needles;)

Next will be the balsa sheeting.

[Kevin Rochon]

Sanded all the stringers flush and started the balsa sheeting on the LH side. Did some patch work and made a new pieces for the side below the door opening. These have lightening holes the front part will not.

[Kevin Rochon]

No work tonight. Stopped at CDN Tire to get stuff to close the pool and pick up some clamps. They didn't have the clamps I wanted but pickup an angle finder, wanted that for a while. also finally picked up a new tool box to replace my old one with the broken handle. It's big enough to put the lipos in it with out being too big and its got metal handle, it is also water proof + it was on special;)

[zorba]

Those are the best protractors in the market. Inexpensive and simple to use. I use it all the time at work. Good choice

[Kevin Rochon]

At 5$ you can't go wrong and it was the last one.

So did some sheeting on the left side tonight. Not too difficult but have to cut the slots for the formers ends. I cut the pieces then put it on then with a hammer I hit it just hard enough to indent their positions.

[mitea_dan]

Tu as besoin de quelques aiguilles.

[Kevin Rochon]

J'ai du en mettre quelques une du côté droit;)

Tonight the right side. I had to make it in several pieces and put some support pieces where there was no ply support. That's where the old meets the new below the window(you can't see those supports).

[mitea_dan]

C’est beaucoup mieux. Mai, pour le travail délicat, est besoin des aiguilles plus mince.

[Kevin Rochon]

Tonight just removed the clamps and needles and since it's easier now I cut the slot for the door latch and tested it with the door it fits just right, I will glue it on only after the covering.

[Kevin Rochon]

Did the sheeting for the top of the dash. I used tape for clamps as it's a curved section. The side are 3/32" and the top 1/16" so will be the bottom.

[Kevin Rochon]

OK I'm going to break the silence;)

Started the 1/16" bottom sheeting. Will look better when putty filled and sanded of course.

[Kevin Rochon]

Now after a little break did the front part, Using mostly Sig wood glue with a bit of Med CA to tack it so I can keep going. Since it's plywood underneath it's too hard to use needles. I will be cutting 2 big holes in that sheeting(last pic is from Bigfoot #1)

[Kevin Rochon]

After a bad night(didn't sleep much) did some chores outside and finally had enough strength left to do the final sanding and make the hole on the bottom sheeting. Also installed the bottom door magnet.

[Kevin Rochon]

Thanks to Michel and good timing got my new windshield. A little more putty and sanding also painted the dash and upper part. Glued in the door magnet. Next step should be covering.

[Kevin Rochon]

Tonight did the white Ultracote covering of the bottom & sides, barely had enough left to do the job so did some paper cut outs for the sides. Managed to cut one up side down but fortunately had enough to finish:rolleyes:

[Kevin Rochon]

Did the black top part tonight, while watching Airplane repo;). Next step the stripes.

[Sempai-mj]

Looks like it will be better than new soon.

[Kevin Rochon]

Thanks Michael. Well trying to but I still have a few stubborn wrinkle to deal with.

[zorba]

don't worry about the wrinkles...it will fly fine just the same..looking good.

[Kevin Rochon]

don't worry about the wrinkles...it will fly fine just the same..looking good.


you're right Billy I've got wrinkles and I guess I can fly nice:D

[Kevin Rochon]

Well finished the stripes after a lot of calculations comparing etc. Left to do:

-Making new hinges for the door top.
-Installing the windshield.
-Making new landing gear fairings(too far gone)
-Re install the tail wire braces
-Install landing gear and tail wheel assy.

[beto9]

Kevon, I have a Stick type plane to repair. Interested? Not much to do, just to fill your winter days/nights.... :D:D

[Kevin Rochon]

Who's Kevon? another repair guy;)

I guess, but let me finish this and the wheel door on the Harvard, so for once I'd have the fleet in running order...what a dream:rolleyes:

[Kevin Rochon]

Did the new door hinges also installed and aligned the door latch bracket and glued in the door latch. Glued in the windshield.

[Kevin Rochon]

I made some black strips to cover the top and side of the windshield borders(bottom comes already done). Put back the wires bracing in the tail and installed the main and tail wheel LG. Next to make the new LG fairings but not today I'm invited to a surprise party for the retirement of my neighbor, lucky guy and he's younger then me:rolleyes:.

[Kevin Rochon]

Cut assembled the new fairings, you can see the old ones, too broken to reuse.

[Kevin Rochon]

Hum oops:o made the fairings in the wrong grain directions. So when I took off the clamps it was already curving so had to redo them.

[Kevin Rochon]

Lazy Saturday...thought of doing some work outside but was a bit too windy to cut shrubs...:rolleyes: So did the covering of the bottom of the fairings, had to do some sanding first and trial fit to adjust it to the fuse bottom.

[Kevin Rochon]

So tonight did the top of the fairings.

[Kevin Rochon]

Well it's done. I kept a few of the old parts like the electric motor mount in case to make a new one. Cleaned up the shop.

Now look what's back in the shop. Need to fix that gear door.

[mitea_dan]

Peut être c'est le temps de changer l'horreur électrique avec un vrai engine.

[Kevin Rochon]

Tu voulais dire moteur et non horreur car moteur c'est électrique et engin c'est à gaz;)

[Kevin Rochon]

Today I finally got the light system to work so the red and green are flashing and got the landing lights on a servo switch. Just have to install it in the Bigfoot and transfer the servos from the wing with no light to the other ones.