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Old 05-03-2017, 05:47 PM   #1 (permalink)
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Default Super Scale Jayhawk Re-Build

For those that made it to the Scale Rotors Over Panama City and saw the Super Scale Jayhawk go down, I have been tasked with repairing the fuselage. It got busted up a little. Mainly the rear landing gear collapsed up inside the fuse, it shattered the cross member it was attached to. The weight of the batteries broke the batt. box out, that took out the cockpit. The lead weight that had to be put up front for ballast caused the windscreen side frames to shear off when it flexed down. Not an overnight fix but, it will fly again. It gives me a good reason to throw all the crap out of my shed and make a proper paint booth!

Some pics.

Ron
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Old 05-04-2017, 06:26 AM   #2 (permalink)
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Yikes. What a shame, but like you said, it does look repairable.

Question... How do you go about repairing the gel coat? Is it just a matter of using autobody glaze to fill it in and feather it out? Just curious how you do it. I use http://www.autobodytoolmart.com/usc-...2-p-30946.aspx. Works absolutely awesome.

Was this a turbine bird or electric and what brand of fuselage?

Good luck with the repair!
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Old 05-04-2017, 09:03 AM   #3 (permalink)
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Yeah, what a shame. The tail gears stripped in flight causing a flat piro spin. He was able to keep it flat and hit throttle hold about 8 or 10 feet. It could have been a lot worse. I will pick out the loose gel-coat and feather the edges. I use some stuff called Nitro-Stan spot and glazing putty to fill in and then sand back. I will wet sand the entire fuse and repaint. This was an electric Roban from RC Aerodyne with about 20-25 flights.

Ron
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Old 05-12-2017, 05:02 PM   #4 (permalink)
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Ok, the first thing to do is get her back on her feet. The fuselage on the bottom is broken at the rear gear access hole and the first cross member of the main mechanics mounting. I used CA glue on the outside to hold it together then laid glass on the inside. The cross member that the rear gear mounts to had shattered so, I cleaned it up and made a new, solid cross member. I glued the two sides in with Gorilla Glue. I like the way it foams and gets into all the crevices. Then glassed over it. I will be making some "I" beams to go forward to the main mechanics mount just to take up any flexing with a hard landing.


Ron
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Old 05-12-2017, 09:08 PM   #5 (permalink)
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Much better. I am surprised it didn't bust under its own weight just sitting there. It should be fine once you have got her rebuilt. Take care.

Don
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Old 05-16-2017, 01:34 PM   #6 (permalink)
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Thanks Don,
The next step is the front gear mounts. The outside part of the mount that the strut mounting screw just sits in broke off from the mount. I don't like it just sitting there without as much as a bushing so I am going to install a "T" nut on that side as well. Then the screw or "pivot pin" will be fully supported on both sides. The box on the starboard side broke loose as well, so I took it out to repair. Will do the same for the other side. and glass them in place.
Maybe a daub of hysol in the inside to make contact with the fuse as those 4 tabs are all that is holding the weight.

Ron
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Old 05-16-2017, 08:05 PM   #7 (permalink)
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Ok, so I have the new "T" nuts installed and glued in with gorilla glue. The back plate glued on and bead of glue around it all. Now there is a proper axle. I am still debating on a layer of glass over it. Then putting the boxes back in and glassing in place.

Ron
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Old 05-16-2017, 11:40 PM   #8 (permalink)
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Definitely glass the part, thaw have you thought to maybe make the part new out of glass fiber?

Keep up the good work,

Peter
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Old 05-17-2017, 07:03 AM   #9 (permalink)
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Thank you Peter,
After looking at the parts this morning the glue has foamed and cured and my assessment is there is no need to glass over it. The Gorilla glue is plenty strong, stuff is amazing. These parts will be glued back in and then glassed in place. I keep kidding the owner it will be so strong that he will be able to do rolling auto rotation landings down the runway .

Ron
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Old 05-17-2017, 07:58 AM   #10 (permalink)
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Hey Ron, ok if it looks strong enought than by all means use it.

Peter
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Old 05-17-2017, 10:08 AM   #11 (permalink)
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I just glued the boxes back in. I put a dab of Hysol on the back side to bond it to the fuse. Later I will glass in place along with strengthening a couple of ribs with glass.

Ron
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Old 06-15-2017, 09:54 AM   #12 (permalink)
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Ok, back at it. I took a little time to go visit the folks and now feel that I am falling behind as we want it done and some testing flights before the big event in Dalton.
So I needed to make some braces that would help carry the load in a hard landing. I cut some strips of 1/8 ply, glued them together, cut and bonded in place. This should help carry the load forward to the main structure rather than ripping the fuselage apart. Also, some stronger springs will be needed in the struts as they were bottomed out sitting still.
I also got the front pulled back into place and tacked in. Need to re inforce the areas that sheared off from all of the counter weight up front. Maybe a brace across the front to tie into the main structure to help support it as well.
The battery box is repaired and strengthened all the seams and glassed on the inside. Almost ready for a fiberglass party to bond every thing together.

Ron
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Old 07-04-2017, 01:38 PM   #13 (permalink)
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Happy 4th of July! Been a little slow going lately. I had to strengthen around the door hinge post and windshield arm so, I bonded in some carbon fiber rod around the door frame with gorilla glue, ground it back and glassed over it. It is very strong in this area now. Will trim it out tomorrow and brush in some gray paint to cover. You can see the carbon rod in the pic.

Ron
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Old 08-06-2017, 02:47 PM   #14 (permalink)
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well, it had been a while since posting. I kinda got on a roll so, here is where I am now. I didn't like the way the doors fit so they have been re-shaped to fit into the door pocket better. The horizontal stab. has been attached to a servo to raise up when the landing light is turned off. The inside has been painted gray, and the outside looks like this now. Hope to get the clear on tomorrow.

Ron
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Old 08-12-2017, 01:15 PM   #15 (permalink)
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Well. I've done all I can do so it is time to give it back to its owner. He will give it a 1200 grit wet sand, polish and install the decals. More pics. to come.
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Old 08-12-2017, 06:42 PM   #16 (permalink)
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WOW, you can fix my crashed helicopter bodies, anytime. Nice job.

Don
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Old 08-13-2017, 05:34 AM   #17 (permalink)
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Nice Job indeed, bravo great result !

Peter
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Old 08-13-2017, 08:02 AM   #18 (permalink)
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Thanks guys, it was pretty banged up but, it is now stronger than ever. The owner is very happy with it. I keep kidding him that he can do full on auto rotation with a rolling landing lol.
This build has given me cause to look for weak spots in my current build (funkey MD 500E) and strengthen accordingly.

Don, I will see you at Dalton. I am looking forward to it.

Ron
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Old 08-13-2017, 10:01 AM   #19 (permalink)
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Beautiful work, looks better than new! I love what you have done with the H-stab as well, I may end up doing that to a 500 Apache that I am working on. Can't wait to see it when all the decals are applied!
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Old 08-16-2017, 07:18 AM   #20 (permalink)
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Ok, we got some decals put on. It looks better than new. Can't wait to see it in the air.

Ron
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