a couple printed widgets

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A2022
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Re: a couple printed widgets

Post by A2022 »

rib wire support. also, thinking about some kind single wire support at a rib. same methodology as the conduit support but fumbling around with the wire attachment method. just trying to get a basic shape at this point.

KONGOS - Come with Me Now
https://youtu.be/Gz2GVlQkn4Q

KONGOS - Come with Me Now (mixed Instrumental)
https://youtu.be/QhLCSXWBlUk

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I made a feature for a zip tie and snugged the bracket to be closer to the edge of the hole to minimize size. It could be OK for bottom dead center or offset +/- 30 degrees or so. like the guy said, "if you want a job for life, make brackets". :)

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Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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A2022
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Re: a couple printed widgets

Post by A2022 »

RV10 window mount jig idea....

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Hi Steve. Dustyone on VAF posted this little jig to help with window spacing during installation.

https://vansairforce.net/community/show ... stcount=37

Are you able to make these? I'd be interested.

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I was too pricey, but if someone wants to try a couple of these for fit, let's do it.




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Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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A2022
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Re: a couple printed widgets

Post by A2022 »

rib wire support pull test. it lifted the table at 115 lbs. enough room for a couple zip ties. apply some RTV to secure the wire in place in the trough and it is relatively easy to remove but yet secure. I initially drilled the holes in a stupid place and could not attach the sheet metal to the vise, so I need to drill it out and re-rivet. I could not see any adverse visual effects on the wire support after the pull testing.


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Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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A2022
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Re: a couple printed widgets

Post by A2022 »

rib wire support using a p-clip. endless possibilities...




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Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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Re: a couple printed widgets

Post by A2022 »

maybe a simple box and add a couple recessed holes, follow along. make the sketch so that the box is easily adjustable to whatever size is needed. let the holes control the size. extrude the box, then recess a couple holes. change the dimensions of the recessed holes that are needed, and the box automatically adjusts to minimum size to make it work. perhaps you want one of recessed holes to be tapered and the other straight, or either or. omit the holes if you just want a box for some reason. 10 minutes and you're done. take a break, you deserve it! :)

if you wish, you can make a design table so that you input the value you wish in a spreadsheet and the part generates automatically, then beam it to the printer.

I have been grounded for the past 6 days because no BFR, but it seems it may happen tomorrow. then I can throw the bike in the plane and get the heck out of here.

Yotto - 'Just Over' (Official Audio) [Odd One Out]
https://youtu.be/kFhxUaAS0nc


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huevos rancheros with habanero sauce has my name on it. double the burn with hot coffee!

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Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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Re: a couple printed widgets

Post by A2022 »

2-inch-wide air dams with vortex generators. I took my BFR Saturday. on the way home, descending into the airport I heard the whistle sound. I asked my check ride pilot if he could hear it, but he could not. he has some hearing aids and says his hearing is not good, but I could hear it. neat flow plastic flow lines into the generator fins. not much added fin weight to these. first two of these to print, not perfect, but good enough for testing.

Marsh - Lailonie (Official Music Video)
https://youtu.be/9XFkGCQzV8U


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to replace these...

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Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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Re: a couple printed widgets

Post by A2022 »

2-inch-wide winter cowl inlet air dams with turbulators installed. I am hoping the turbulators cure a faint whistle I hear when I am 140+ kts. I hope that's all they do and that they do not cause any other problems because the air dams without turbulators are great except for the whistle. I think the 2-inch air dams are causing the whistle because I didn't hear it with the 1.5-inch-wide air dams. these air dams are hollow like a balloon.

Way Out West - We Love Machine
https://youtu.be/pX910vSInzA


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yep, these air dams eliminate the whistle. I think the turbulators are adding some additional blockage because my CHTs were up 5F over the non-turb version. 0C OAT at 6500 ft, 65% power, CHT 1-3 were 320 +/- 2F, but CHT 4 was 340F. CHT 4 had been creeping up over the past year to run +15F hotter than the others. I probably need to do some baffle work around #4. max speed during this testing was 166 KIAS, 178 KTAS. I will keep these air dams for the remainder of the winter.


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in order to get some additional air to #4 cylinder, I angled the top and removed one turbulator from the short side. I am not sure this will work.


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leveled the upper gap to cowl on the right-side air dam. I noticed #2 CHT dropped 5F. #4 CHT came closer in-line with the others. 2" wide are probably good until late January, then change to 2.5" wide for February. OAT = -5C today at 6.5K ft. good CHT cooling in extended hard climb, less than 360F, cruise ~315F.

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3 minutes from our house is Thai Taste. I tried their "Lava" dish with a spice level of 8/10. my wife choked on this level 8. :) really good, but next time I will get spice level 11/10. with pork, man that was good, can't get it out of my head.

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2.5 inch wide with turbulators


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Last edited by A2022 on Sun Jan 15, 2023 12:14 pm, edited 6 times in total.
Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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Re: a couple printed widgets

Post by A2022 »

flap cover lift buttons are holding fine.


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Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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A2022
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Re: a couple printed widgets

Post by A2022 »

2.5 inch wide air dam with turbulator test fit, significant blockage, but not flight tested yet. the right-hand side is done but I misdrilled the left-hand side, so it is scrap. I ask the Gods; how can I do stupid stuff like this? today the OAT on the ground was 10C but 0C at 6.5K ft. using the red 2-inch-wide air dam my CHTs were 335-345F and oil temp was 190F (fully tape blocked). OK in the climb because the air can go over the top of the dam. 50 hrs on the oil, I'm having a hard time getting around to changing it. windy today, not many flying. large ground speed change, no altitude change (winds howling). if I lost a brake, my big rudder may have kept me on the runway. if I had a small rudder, no chance.


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Darth Vader, left-hand side now installed. need a cold day for testing, -5C or so on the ground.


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I didn't get -5C on the ground but rather +4C but flew anyway. CHT were 340-350 at 4K ft and the OAT = 0C. they were good in the climb and didn't see CHT over 360F. so, cooling is pretty good in the climb and blockage is good in cruise. I was happy with them.

when they are black color, they are almost invisible.

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Last edited by A2022 on Tue Jan 24, 2023 10:27 pm, edited 1 time in total.
Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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Re: a couple printed widgets

Post by A2022 »

conduit support.... working to find the proper clearance for the conduit supports. I have a nice snug fit on these. the measured conduit OD is pretty close to the listed but not exactly. these conduits are from Heyco (same suppler for the snap bushings) and are flame retardant UL94-0. they are certified to extinguish any burning within 10 seconds. I'll test for that.

I had some Van's conduit but threw it away because I was busy building a loft and really cramped for space. I'm not sure of the Van's conduit rating. I believe the Heyco conduit is stiffer than the Van's, if I remember correctly.

I don't know why there would be a need for anything larger than 21mm nominal diameter.

these are 13, 16, 21, and 28 nominal diameter.

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my measurements

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Heyco sizing and UL rating definition

UL-94 is the Standard for Tests for Flammability of Plastic Materials for Parts in Devices and Appliances. Within this standard, materials are subjected to various burning tests to see their performance in flammable conditions. Flammability UL 94 V method “evaluates both the burning and afterglow times after repeated flame application and dripping of the burning test specimen” in a vertical burning test.

To attain the UL 94V-0 standard, samples must have met the following criteria:

Burning combustion is not sustained for more than 10 seconds after applying controlled flame.
Total flaming combustion time for 5 samples does not exceed 50 seconds.
None of the samples burned up to the mounting clamp by either flaming or glowing combustion.
None of the samples dripped flaming particles that result in the ignition of the surgical cotton below them.
Samples did not exhibit glowing combustion for more than 30 seconds after removing the second controlled flame.


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Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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Re: a couple printed widgets

Post by A2022 »

conduit burn test. impressive!

burn video... if it works....
https://photos.app.goo.gl/o74EjxfZRaC9mEEBA

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checking conduit hanger spacing on a rib. obviously to be installed on the opposite side. looks fine.

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Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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Re: a couple printed widgets

Post by A2022 »

first seat back storage tray to ship to a customer. I am still working on my gluing technique, trying to not make a mess. I have had these installed on both sides of my aircraft for 6 months now and have beat them up, loading and unloading baggage and bikes and they are perfect condition. I am very happy with them and can access the tray when seated. now I need to find a box big enough to ship these. who would have thought I would be printing something so big but only 330 grams. the box may weigh more than the part.


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Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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Re: a couple printed widgets

Post by A2022 »

at the request of HAO line boys. one tow bar to handle all A model RV's. inexpensive, compact and will last a very long time. pull and push, no worries, the handle is locked.


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Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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Re: a couple printed widgets

Post by A2022 »

RV14 canopy fillet sanding block, 3 inches. added a recess in the middle on the backside for a finger hold. I'll send this out for eval.


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Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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Re: a couple printed widgets

Post by A2022 »

RV14 canopy hinge cover nuts with ears. I make these by the hundreds a couple times a year and print them 48 at a time.


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Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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Re: a couple printed widgets

Post by A2022 »

Lightspeed Delta Zulu headset control mount.... this thing is 8.5 inches long and has squeeze button battery release. a direct slide in mount would require 8.5 inch x 2 = 17 inches of total available length. that may be difficult for a small RV aircraft. also, the mount cannot allow the battery release buttons to engage. I am going to need to take a different approach for this mount. follow along to see if I can come up with something in 7 days. at this point I am not sure what it will be.


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Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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Re: a couple printed widgets

Post by A2022 »

firstly, we need to make a representation of the delta zulu control module. for example, this is a model of the Zulu3 module. it is the only way to achieve a perfect fit.

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Delta Zulu control module model. it is a long dongle. must be a computer motherboard in there.

Tinlicker - Oudegracht (Official Tinlicker Channel) ... a good song for my John Wayne dance.
https://youtu.be/Tle_t4kMxO4

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thinking about how to mount this delta zulu.... I have had good results from the fuel sump tester mount, so I think I'll take a look at something similar as a starting point. these are both long and relatively featureless and I need to stay clear of the battery release buttons. leverage a successful design.

Need You (Extended Mix)
https://youtu.be/uwBPKZHGZkA

yeah, I listen to music all day and eat extremely hot 5 pepper breakfast burritos. I'll post my famous 5 pepper burrito one day.

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drop the control module on a plate and think about it. take a break and get some sunshine. printing a lot of carbon fiber parts this week, machines whirling around.


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thinking about the clamp and how to keep the module from sliding fwd. roughing a concept.


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add some fillets tomorrow and it's ready for a test print. I may actually make the 7-day turn time commit.

Tinlicker - Oudegracht (Official Tinlicker Channel) ... a good song for my John Wayne dance.
https://youtu.be/Tle_t4kMxO4


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Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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A2022
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Re: a couple printed widgets

Post by A2022 »

nylon / carbon fiber parts that need hole cleanup.


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Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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A2022
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Re: a couple printed widgets

Post by A2022 »

Lightspeed Delta Zulu headset control mount... test fit. it's a very good fit and perfect install motion. it is locked in all three planes. I may want to try one adjustment for curiosity's sake after I cycle it a few times. I don't think I have ever had one so good on the first attempt. I will definitely make my 7-day commit date and may beat it by 2 days.


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Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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A2022
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Re: a couple printed widgets

Post by A2022 »

Bose A20 headset control mount. first time to print these in dark grey color. they look good.


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Steve Melton
N531EM, RV9A, Superior O-320, WW 200RV prop, Slick mags, CHT 330F, EGT 1300F, B&C, 1200+ hours
Freedom and Democracy are all that really matter.
Ride a bike, unlock the world.
https://www.rvplasticparts.com/
https://www.gpsdock1.com/

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