a couple printed widgets

A forum for the proverbial airport bum who just wants to talk about anything and everything related to flying. Introduce yourself here !!

User avatar
A2022
Class D
Posts: 280
Joined: Sat Mar 05, 2022 8:52 am
Location: Cincinnati, OH
Contact:

Re: a couple printed widgets

Post by A2022 »

seatback tray updated analysis...... I doubled the number of nodes and did another thing to reflect the model detail to achieve a more accurate result. 900K nodes and needed to run overnight. a common practice is to make an FEA model and review the results and then double the elements and look at it again to understand the stress concentration areas better. the refined model stress is 10% higher and within limits. looking good.

these elements have mid-side nodes that improves accuracy.

analysis for ultimate 20 lb loading. this would be when the tray is loaded with 3.3 lb and pulling 6g.

Image

Image

Image

Image

Image

Image

Image

***********

from somewhere in the mountains, to see a 3D printing guru by the firelight, spooky. Luke, you must feel the force. .... not as fast as an RV

Image
Last edited by A2022 on Mon Aug 22, 2022 9:25 am, edited 1 time in total.
Steve Melton
RV9A, Superior O-320 (roller cams), WW 200RV prop, Dual impulse slick mags, CHT 330F, EGT 1300F, Oil pressure = 65 psi, B and C Alt, 1000+ hours
Freedom and Democracy are all that really matter.
https://www.rvplasticparts.com/

User avatar
A2022
Class D
Posts: 280
Joined: Sat Mar 05, 2022 8:52 am
Location: Cincinnati, OH
Contact:

Re: a couple printed widgets

Post by A2022 »

seatback storage tray..... day 2, 20 lb load test. well, I screwed the pooch and forgot to remove the lead weights before today's flight. I did a couple zooms and it was moderately bumpy. the landing was OK. I remembered the lead was still in the tray about halfway into the flight. however, everything was still there in place when I got back. there's another data point. I don't know if I should remove the tray now for inspection now or wait.

Image
Steve Melton
RV9A, Superior O-320 (roller cams), WW 200RV prop, Dual impulse slick mags, CHT 330F, EGT 1300F, Oil pressure = 65 psi, B and C Alt, 1000+ hours
Freedom and Democracy are all that really matter.
https://www.rvplasticparts.com/

User avatar
A2022
Class D
Posts: 280
Joined: Sat Mar 05, 2022 8:52 am
Location: Cincinnati, OH
Contact:

Re: a couple printed widgets

Post by A2022 »

seatback storage tray....day 3, I left the tray in place and inspected around the edges. looks good. unload the tray and went for a flight then reloaded the tray with the 20 lbs. everything is in perfect condition with this ultimate loading so far. load testing is ultimate 20 lb loading. this would be when the tray is loaded with 3.3 lb and pulling 6g. I am becoming faster at loading and unloading the lead weights. :)

Govi, Sails of Joy
https://youtu.be/Z5rrmPDGuWM

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

Smoky Mountain Half Marathon getting close and I'm getting pumped.... a beautiful place to run!

hitting 50 pushups per day after a run.

the plan is same as last year.
1. fly there
2. eat like a pig to carbo load
3. run and win the race for my age group (60-64), but little chance of that because there are some world class runners there but hoping for a top 5 place
4. recover and eat like a pig
5. fly home

from what I have found, when you show your race results to the doctor, it sure is easy to get signed off for a medical. :)

Image
Steve Melton
RV9A, Superior O-320 (roller cams), WW 200RV prop, Dual impulse slick mags, CHT 330F, EGT 1300F, Oil pressure = 65 psi, B and C Alt, 1000+ hours
Freedom and Democracy are all that really matter.
https://www.rvplasticparts.com/

User avatar
A2022
Class D
Posts: 280
Joined: Sat Mar 05, 2022 8:52 am
Location: Cincinnati, OH
Contact:

Re: a couple printed widgets

Post by A2022 »

seatback storage tray..... day 3,4,5, 20 lb load test. day 5 I went for a flight and forgot to remove the weights again. this tray is getting a workout. prefight check was good, but I don't have this in my routine, I need a sign.


Image

Image

Image
Steve Melton
RV9A, Superior O-320 (roller cams), WW 200RV prop, Dual impulse slick mags, CHT 330F, EGT 1300F, Oil pressure = 65 psi, B and C Alt, 1000+ hours
Freedom and Democracy are all that really matter.
https://www.rvplasticparts.com/

User avatar
A2022
Class D
Posts: 280
Joined: Sat Mar 05, 2022 8:52 am
Location: Cincinnati, OH
Contact:

Re: a couple printed widgets

Post by A2022 »

seatback storage tray..... day 6,7, 20 lb load test. day 7 unload, fly then reload. tried to get some photos of the high stress corner areas. no signs of distress on anything. everything is tight and secure. August in Ohio has been wet, everything is green. Low temp tonight is 15C so it's beginning to become very nice weather. the world is beautiful from up there. que the music. Nothern Cincy airspace is normally busy but not tonight, I had the sky to myself after the last student landed at HAO.

Ben Böhmer - Purple Line (Original mix)
https://youtu.be/r6s6K-b1QkQ

Image

Image

Image

Image

Image

Image
Steve Melton
RV9A, Superior O-320 (roller cams), WW 200RV prop, Dual impulse slick mags, CHT 330F, EGT 1300F, Oil pressure = 65 psi, B and C Alt, 1000+ hours
Freedom and Democracy are all that really matter.
https://www.rvplasticparts.com/

User avatar
A2022
Class D
Posts: 280
Joined: Sat Mar 05, 2022 8:52 am
Location: Cincinnati, OH
Contact:

Re: a couple printed widgets

Post by A2022 »

rudder gust lock using a bungee with a rope limiter. I'm still thinking about what sheathing to use for this. obviously, this one is too big. need to look for something else. this concept may work for a taildragger, where some allowed motion is provided by the bungee. the rope limiter can be set to any dimension as a hard stop.




Image

Image

Image

Image
Steve Melton
RV9A, Superior O-320 (roller cams), WW 200RV prop, Dual impulse slick mags, CHT 330F, EGT 1300F, Oil pressure = 65 psi, B and C Alt, 1000+ hours
Freedom and Democracy are all that really matter.
https://www.rvplasticparts.com/

User avatar
A2022
Class D
Posts: 280
Joined: Sat Mar 05, 2022 8:52 am
Location: Cincinnati, OH
Contact:

Re: a couple printed widgets

Post by A2022 »

seatback storage tray..... day ?, 20 lb load test. day whatever, I'm losing count. unload, fly and reload. hey, lifting 20 lbs into the cockpit is heavy. another seatback tray printed in dark grey this time.

The Dualz - Your eyes (Live) /// Anjunadeep
https://youtu.be/bu4AP-HQWbU


Image

Image


Image
Steve Melton
RV9A, Superior O-320 (roller cams), WW 200RV prop, Dual impulse slick mags, CHT 330F, EGT 1300F, Oil pressure = 65 psi, B and C Alt, 1000+ hours
Freedom and Democracy are all that really matter.
https://www.rvplasticparts.com/

User avatar
A2022
Class D
Posts: 280
Joined: Sat Mar 05, 2022 8:52 am
Location: Cincinnati, OH
Contact:

Re: a couple printed widgets

Post by A2022 »

thinking about an exterior acoustic hush panel for the exhaust pipes to keep noise and vibration outside the aircraft. I may attach it with velcro. :) but I don't want air to get under it, however. I will probably have to make this from two pieces.


Image
Steve Melton
RV9A, Superior O-320 (roller cams), WW 200RV prop, Dual impulse slick mags, CHT 330F, EGT 1300F, Oil pressure = 65 psi, B and C Alt, 1000+ hours
Freedom and Democracy are all that really matter.
https://www.rvplasticparts.com/

User avatar
A2022
Class D
Posts: 280
Joined: Sat Mar 05, 2022 8:52 am
Location: Cincinnati, OH
Contact:

Re: a couple printed widgets

Post by A2022 »

in-process parallel printing some brackets. if you print using this method, it is good to have the printed parts close together to minimize travel moves.

Tinlicker - Rebirth (Ft. Hero Baldwin) [Official Video]
https://youtu.be/owNOQeplt0Q

Image

Image
Steve Melton
RV9A, Superior O-320 (roller cams), WW 200RV prop, Dual impulse slick mags, CHT 330F, EGT 1300F, Oil pressure = 65 psi, B and C Alt, 1000+ hours
Freedom and Democracy are all that really matter.
https://www.rvplasticparts.com/

User avatar
A2022
Class D
Posts: 280
Joined: Sat Mar 05, 2022 8:52 am
Location: Cincinnati, OH
Contact:

Re: a couple printed widgets

Post by A2022 »

ABS complex part. printed well in a heated chamber. ABS is a good printing material if you can exhaust the fumes.


Image
Steve Melton
RV9A, Superior O-320 (roller cams), WW 200RV prop, Dual impulse slick mags, CHT 330F, EGT 1300F, Oil pressure = 65 psi, B and C Alt, 1000+ hours
Freedom and Democracy are all that really matter.
https://www.rvplasticparts.com/

User avatar
A2022
Class D
Posts: 280
Joined: Sat Mar 05, 2022 8:52 am
Location: Cincinnati, OH
Contact:

Re: a couple printed widgets

Post by A2022 »

seatback bar storage tray.... 3 weeks of ultimate static load testing (20 lb). it's looking good. I'll let this run for a month. unload, fly, reload. a beautiful calm day (with music)! the sky is normally busy around northern Cincinnati, but not today. I had the sky to myself.


Image

Image

Image

Image
Steve Melton
RV9A, Superior O-320 (roller cams), WW 200RV prop, Dual impulse slick mags, CHT 330F, EGT 1300F, Oil pressure = 65 psi, B and C Alt, 1000+ hours
Freedom and Democracy are all that really matter.
https://www.rvplasticparts.com/

User avatar
A2022
Class D
Posts: 280
Joined: Sat Mar 05, 2022 8:52 am
Location: Cincinnati, OH
Contact:

Re: a couple printed widgets

Post by A2022 »

half marathon results. I could not break into the top five. I still suck. maybe next year!

at this rate, I'm going to need to run until I'm 75 to get into the top five.....

but hey, my wife and I had a really fun time pretending we are athletes. she was 3:21 walking. Knoxville was good to us.

I only have one excuse; it was raining so hard my music shorted out at mile 8. I need "mah music"! :)


Image

Image

Image

Image

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

made it to the finish line. it was a wet one. need to find a way to become faster. thinking about next year!

Image
Last edited by A2022 on Fri Sep 16, 2022 6:54 am, edited 3 times in total.
Steve Melton
RV9A, Superior O-320 (roller cams), WW 200RV prop, Dual impulse slick mags, CHT 330F, EGT 1300F, Oil pressure = 65 psi, B and C Alt, 1000+ hours
Freedom and Democracy are all that really matter.
https://www.rvplasticparts.com/

User avatar
A2022
Class D
Posts: 280
Joined: Sat Mar 05, 2022 8:52 am
Location: Cincinnati, OH
Contact:

Re: a couple printed widgets

Post by A2022 »

seatback bar storage tray.... 4 weeks of ultimate static load testing (20 lb). results from the 20 lb load test resulted in 1 small crack at one corner where the highest stress was predicted by analysis. the crack is small and did not propagate through. I am deeming this acceptable since the service load for this tray is 3.3 lb and the 20lb represents a +6g loading. the 3M dual lock velcro was secure at all locations. compared the load test tray (black) to a new tray (grey). installed the new grey tray. tray weight = 325 grams.

Image

Image

Image

Image

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

analysis for ultimate 20 lb loading. this would be when the tray is loaded with 3.3 lb and pulling 6g.

Image

Image

Image

Image

Image

Image
Steve Melton
RV9A, Superior O-320 (roller cams), WW 200RV prop, Dual impulse slick mags, CHT 330F, EGT 1300F, Oil pressure = 65 psi, B and C Alt, 1000+ hours
Freedom and Democracy are all that really matter.
https://www.rvplasticparts.com/

User avatar
A2022
Class D
Posts: 280
Joined: Sat Mar 05, 2022 8:52 am
Location: Cincinnati, OH
Contact:

Re: a couple printed widgets

Post by A2022 »

headset mounted with 3M Dual Lock (hard Velcro) is still holding after a year. the first test survived exactly one year and used 4.5 yr old 3M Dual Lock that was sitting on a shelf in the hangar. this time I used 1 yr old Dual Lock and scuffed the backside of the mount. it is exposed to hot and cold of a non-conditioned hangar in Ohio and has some vibration from the air compressor. the weight the mount is supporting is 1.1 lb at the end of the arm. the test will continue.....


Image
Steve Melton
RV9A, Superior O-320 (roller cams), WW 200RV prop, Dual impulse slick mags, CHT 330F, EGT 1300F, Oil pressure = 65 psi, B and C Alt, 1000+ hours
Freedom and Democracy are all that really matter.
https://www.rvplasticparts.com/

User avatar
A2022
Class D
Posts: 280
Joined: Sat Mar 05, 2022 8:52 am
Location: Cincinnati, OH
Contact:

Re: a couple printed widgets

Post by A2022 »

RV9 flap appendage closure. I like the RV9 flap because it is lightweight and simple with superb operability (actually, amazing, good). however, there is an appendage on the inboard side that leaves both a step and a gap. is it a real problem, no, but I want to clean it up. I don't like things fluttering in the breeze. I believe a small button shaped like a football will work and a 90-degree angle piece. I will install these plastic pieces without removing any other aircraft parts. the RV9 flap bracket fairings are original and approaching 5 yrs, if I remember correctly.

I'll probably get 3 kts from this. :)



Image



Image



Image


Image

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

I can surely obtain 100 psi shear strength from this flexible adhesive. I didn't bother to scuff the paint, but rather just cleaned it. the button bond surface area = .237 inch ^2. 100(.237) = 23 lb capability. the force required to support the appendage = approx 0.2 lb. 23/.2 = 115 safety factor. the button is only loaded when the flaps are up, so that is relatively short duration for my aircraft. not much time for the adhesive to creep. the button should have a good long life. the plan is to set the buttons firstly, then add the angle piece to cover the slot using the same adhesive in a couple locations, doesn't need much.




Image

Image
Steve Melton
RV9A, Superior O-320 (roller cams), WW 200RV prop, Dual impulse slick mags, CHT 330F, EGT 1300F, Oil pressure = 65 psi, B and C Alt, 1000+ hours
Freedom and Democracy are all that really matter.
https://www.rvplasticparts.com/

Post Reply