Alky6
150cc
Started on the lightening process of the fuse halves. Not pleased with the results. The weight reduction is in line with what I calculated, however, the outer skin is now not supported very well and can easily deflect and crack. I did leave a little bit of the honeycomb,hoping that would help, but without the other skin, it almost provides no support. I am going to go back to my original plan and cut the height of the fuse side down 1.5”. Each fuse side weighs 9.03 oz before lightening, with most lightening done it is 7.32 oz. Taking the 1.5” off will get down to 6.5 oz with no lightening. The lightened fuse side also became much more flimsy than anticipated. Oh well. Learning process...
Snoopy1
640cc Uber Pimp
It does not surprise me it was like when I was playing around with styrofoam wings. Cutting holes and all sorts of crazy things were being done. Played with that concept and it was a lost cause all that happened was the wing was a lot weaker in relationship with weight loss never did it again.
Alky6
150cc
My biggest concern is the brittleness in the outer skin where I removed a lot of material. Before giving up, I should see if I can add some reinforcement back in to provide support that isn’t heavy. The last thing I want to happen is have a fuse you can’t handle for fear of breaking. I also don’t want to have to add a bunch of extra formers that add unnecessary weight. I’ll play with it and see where it goes.
pawnshopmike
Staff member
Maybe try drilling some 1” holes to lighten it up instead of milling? Might not be as light but I would thing it would be a lot stronger.
Alky6
150cc
That is a great idea. Logistically, will need to get creative on how to accomplish it. Maybe I go with a bunch of 1/2" holes and create a pattern out of wood so I can use the router to plunge cut. Cutting this stuff requires a carbide tool and will need to be an end mill or router type of bit as to not pierce the outer skin. A lot of work, but I would probably be able to get the weight down to the same as previously anticipated since I could remove more material in more areas. Thanks for the idea, Mike! It is all about the build anyway...
Snoopy, I do have more material. In fact, when I was cutting the first set of fuse sides I roughed out a second set from the sheet since I already had the fence set on the table saw. I will start over, but I may play around a little more to learn before heading down path b.
Snoopy1
640cc Uber Pimp
One gallon with a DZ200 would not get you through one day of flying. I have YS120 air and I can clean off a gallon in one long day.Late to the party and no YS engines on my shelf. What the heck is going on around here!?
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I do still have a gallon of 30% that's never been opened. You never know. If that DZ200 drops its price one day I may just have to have it to have