When RC airplane tail sections become loose due to flutter or structural fatigue, they can be reinforced by adding flying wires (triangulated copper tubing) and installing additional formers and stringers to distribute loads more effectively; this approach maintains the original lightweight construction while significantly improving structural integrity.
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Deep Dive
Fixing tail issue's on the Classic Bipe!Added:
Well, hello. Welcome back to the RC Baron. I'm your host Mike. It's a pleasure to have you here. Uh as you have as you can tell it's beginning of May and flying season is upon us although the weather here in Ohio could be a little bit better.
Haven't been able to get out to the field too awfully much here recently. If it's not raining, it's too windy or it's cold. I mean, I got the thing.
It's furnace is still running. I thought I would I'm usually done with that by now, but I mean, I have burned 3 bags of pellets in the last week. So anyways, with flying season upon us, it is time to get those works of art out as Josh would say and get get them out to the flying field and let's let's make sure that when they get to the flying field for the first time of the year that they are actually ready to go.
I've already done a couple airplanes. I did the 50 cc profile.
Actually flew it. I think I got three or four flights on it last time I was out at the field. And what else did I do? Um Trying to think what else I've been through. I have I've only been through like two of them so far and I got a bunch of maiden voyages to do. So anyways, I thought take a opportunity kind of between some big projects and get some things fixed up that broke last year and so that's what this video is going to be kind of about. We're also going to dig into some repair work on the classic bike.
All right. So what are we talking here today? Well, we got the classic bike here light out. I love flying this thing.
It's a It's a great flying airplane.
It's got a DLE 60 twin on it. If you haven't seen the what we did to what I did to this to get it back up and flying it was kind of like a revival had been saying for a long time. And we did some work to it, but last year um at the big bird flying in Delphos I was flying it and I was coming across feeling pretty good and I hammered on the throttle just to kind of do a high-speed pass and that was the wrong thing to do to this plane.
Uh it wasn't never meant to fly that fast. So, it is all met a bit over on the overpowered side. This would probably be more like a uh 50cc engine size rather than a 60, but anyways, there's some damage back here.
I caught it. I was getting ready to go fly it. Um but we we induced some flutter back here and with the big control surfaces of the elevator you see just how big this elevator and stabilizer is. Um she was shaking pretty violently. Went to go fly it and I was doing some checks before I throw it in the trailer and I discovered that my elevator uh all of my s- um hinge points had worked them ways worked their selves loose.
Um I did not build this, so I'm not very familiar with the construction techniques used, but I know there was some foam involved. Um this whole turtle deck is foam with balsa covered. Uh these back here are sheeted or that's block wood. I'm not sure what's in here.
I would imagine some sort of thick structure, but I think there's foam in there. And it's just sheeted foam.
Uh but anyways, uh yeah, it was it was pretty violent and I'm also last year when I got this out this joint in here was loose. And I [snorts] injected some uh um Gorilla Glue in there. I drilled several holes across here to get some strength back in it. Uh that worked.
I'll be it on the temporary side because it's loose again now after that violence of the flutter. So, what I've done is is I've taken and I've taken one of my really long light long 8-in drill bit and I drilled a hole from here uh all the way up into this nose cowl about 10 in long and I don't have Yeah, there it is.
And I gorilla [snorts] glued the a piece of carbon fiber in here uh just to try to get some strength in there. If this doesn't work um if this continues to be a problem back here, I'm going to do something else here. You can kind of see a little bit of something telltale sign there of a flying wire.
But, um what I'm going to do is ideally is Now, this is all foam on the fuselage is is uh I think plywood.
It's just a box with foam turtle deck on it, which is an okay way to build, but this is a pretty uh weak area right here. So, ideally um probably the correct way to fix this would be to rip this thing all the way down uh remove this turtle deck, use this turtle deck as a former, much like I did with the Cougar, and build in and build it out of balsa wood um and plywood. [clears throat] And what I would do is is I would uh incorporate some doublers or formers in here in in this area just so we can get a good strong glue joint. Um you could actually probably come in here and remove part of this. I didn't even think about that.
Part of this structure here, slice her off 8-in thick slice some plywood in there and maybe that would uh and if you epoxy that and maybe that would give it some additional strength, but um that'll [snorts] probably be what will eventually happen.
It's just the plane flies too dang good to uh um you know, not uh not keep up on the maintenance and stuff. I don't think that this has been a problem >> [snorts] >> when Mike's dad was flying it, but I think it's a recent problem just because of the age. You can see that it is showing showing its age a little bit with the covering.
Uh did kind of plan on doing maybe a recovering job this winter, but I never got to it, so here we are. So, anyways, the other thing I'm going to do, and this is starting to >> [snorts] >> it's still kind of loose, but all I got is that grill glued in there, so we'll see what that looks like tomorrow after that's had a chance to really set up and cure in there.
And then uh anyways, I'm hoping that this is where we're going to is a set of flying wires back here. So, if you triangulate all this, now you're not going to get strength [snorts] off the rudder. You're going to get the strength off the bottom of the fuselage, so >> [snorts] >> I'm using some I just grabbed this because this is what I had. This is 11/32 copper.
And I'll go through the process of how I bent this up, but um well, it's basically not that big of a deal. You can I I cut it to length, and I shoved this end into the end of my vice and flattened it.
And then uh I measured, and you can see my mark right there.
Uh measured where it was going to end at, and uh um did the same thing on this side, and then I took it over to the the belt sander and radiused the ends off. I think the brass will look all right.
It's more of a classic design, and it's going to give us a heck of a lot of strength back here and not a lot of weight penalty.
So, uh and it sure beats trying to uh rig up some wires. So, I'm going to do this on this guy. Um I got the next piece ready to go.
So, we're going to duplicate this guy over here.
And then uh and then we'll uh um yeah, do the bottom and and tie it all together. I'm using 632 uh bolt set from Dubro to tie it all together.
Got lock nuts.
And uh yeah, so anyways, and then once I get this all uh before the end of the night, I'll go ahead and glue that uh I got to re-hinge this guy.
Probably just move him over a little bit and re-glue and re-drill.
And if I have enough hinges, I might add you know, put one here and then maybe one, two, add three more add three more to the mix just because of how big this is.
So, that'll help uh help reduce that problem spread the load out a little bit more. So, anyways, I'll get set up to do that and uh we'll see how I got that done.
All right, so this is these are pretty simple to do. Um basically, what you're going to do is you need a place to uh put your uh put your hole at. So, you're going to flatten this tube out so that way you can drill it out.
And then um you know, just squeeze it together.
Working with the brass or you know, if you wanted to use aluminum, you could do that, too. This is from K&S.
Um and then basically, I'm just going to try to duplicate this as best as I can.
Um I might end up being a little off here, but that doesn't matter a whole lot.
Uh but we want to when we put this back in the vise, you want to make sure that this is at a 90° angle before you uh squeeze.
Or they're they're in parallel with each other.
So, I'll just tighten the vise up here a little bit and I'll make sure that I'm just eyeballing this stuff. It doesn't have to be super accurate.
And we'll squeeze that end down.
We're not going to put the bend in it yet to uh um for that. We'll do that after we drill the holes. So, I'll turn you around here and we'll get on the uh get on to the drill press here.
All right. So, I got it I got an 8-in bit in here just to just to kind of get things started. And again, I'm just going to uh eyeball the center here.
We'll go ahead and do both sides.
And then, I'm going to swap this bit out for my Christmas tree here.
These things work uh really good for doing this kind of work here because you can uh um the uh the bevel on these, you can actually deburr them, too, while you're while you're drilling this out.
We'll snug that up and make sure she's running straight.
Then, I'll give her a little bit more here.
And we're only going to go to the second step on this guy.
All right. I did is I just went ahead and flipped that over so that way I could deburr this with that channel. You don't have to push much, just a little bit to get rid of the little bit of ring.
Now I'll turn you back over and we'll put we'll match these bends in in the uh copper tubing here.
You're not going to be able to see a whole lot here, but just going to put this guy in here kind of back where we bent it at the first time.
I know that this end with my paper is my top.
So we'll set this in here and see how easy this bends.
And make them kind of the same here.
There we go.
And then we'll put another bend in this end.
Oops.
You do not need to uh get them too close cuz you can fine-tune these guys a little bit once you get them on the plane.
All right, so I'm going to go ahead and get this top one uh reinstalled here.
Like I said, it doesn't really matter a whole lot if you're you know, super accurate here or not, but uh want to make sure they're kind of straight with each other.
So, I know from measuring it before that, you know, I'm like an I'm like an inch away from the edge here, so that's pretty close there.
Uh drill bit is right here.
Now, the biggest thing here is is when you drill through this, you're going to have to use your own idea, but since these are going to be functional, we need to make sure that they're not going to we're not just drilling through um you know, open bay where it's sheeting with nothing in between here.
So, this one we're fortunate enough that I do believe that these are solid sheet balsa.
And uh but anyways, what uh what you want to make sure is that uh you got a hard point in here. Now, if we didn't have hard points in here, we could drill this.
We could drill this out to like a 5/16 dowel rod, and then set it up in our drill press to with a you know, a jig or whatever and drill the 8-in pilot hole down through the center of that.
And then install the dowel rod in here with the 8-in center center bit on it.
And I would do that I would do this and then, you know, use that hole to spot drill the 3/16.
And then you could epoxy that in there.
Now, at that point you could look and see just how much of give you have in there, but um or how much glue you would have. Now, if these were foam, that would be really easy to put 8-in dowel rod in there, but uh if you're doing this on an unknown build, the other thing you can do is go to your trailing edges, right? And that way cuz most of the time anybody that builds an airplane is going to have a hard trailing edge in here.
Or go out to the tip, not go inboard like we got here.
But anyways, I'm really excited to get the other two done. I'm going to basically do the same dang thing that I did here. So, I'll do that off camera.
But um um the next ones will have to I got a longer piece of rod here.
And we're going to pick it up. You probably can't really see it.
But um we will uh I'll put a bolt um in a hard hard part of the hard part of the fuselage. There actually is one right there.
Yeah.
And uh we'll put a wood screw in there to hold it all together and that will significantly improve the uh the strength of the tail section back here.
So, then all I got to do is once I get all that done, um clean all clean everything up, get it all bolted together, um and then uh epoxy my elevator on. So, anyways, we'll finish this All right, another tip that I kind of forgot about during the last segment here was uh you know, making sure you got enough uh rod here to uh span it. And a good way to check is to go ahead and just flatten both ends.
And I'm just putting this up here like it was going to be attached, see?
It's right next to it.
Kind of hard to do one-handed, but I marked the center on this guy where it's going to land. And then I brought this over.
And I mean, it's it's way the heck over here. The center is so my rods are going to rods for the bottom are going to be pretty short.
You know, uh compared to the length of the tubing. So, what I'll do now is is um I'm going [snorts] to mark the fuselage sides on the rod here. I'll drill my hole, bend it, and get it to where it's angling down this way.
And then I'll mark the side of the fuselage and and then I'm going to bring each one over. And I'm going to overlap these into one piece. I got a nice thick piece of plywood right here on the tail right in front of the tail wheel. Uh got a hole there, but it's pretty long. So, I can screw into this guy and harden these threads, and then uh it won't go anywhere.
Uh if I do have a problem, I guess I don't really have a hole back here to be able to put a blind nut in.
Uh ideally, it would have a blind nut in, but uh hardened threads would work just fine, too.
Uh but anyways, I'll go ahead and do that, and I'll do that to both sides.
And then where I mark it at, that's where I'll start the flattening process cuz I don't want want it to be up here.
You know, I don't want tubing here. I want it to be all flat all the way across this this wing surface. Your mileage may vary dependent on how big or not you know, what your particular model is.
Uh Uh, another thing you can do, and I'm not going to do it here, but with your tail wheel assembly, you could um, especially if you had like, uh, a different one than that, like one of the flat spring styles, uh, you could go to one of those bolt holes, too.
And, uh, you know, screw your screw your, uh, um, flying wire down to it.
You know, kind of cuz it's going to be strong enough for a tail will be strong enough for flying wire.
Uh, any you know, this is just one way of doing this stuff. I mean, you don't have to use >> [snorts] >> you know, you could go you could flatten the one section out, cut it, and put a couple holes in it, and then run cable between it if you wanted to go to that extreme. This is a lot more simpler, though.
So, and it's going to give us the strength we need. So, anyways, I'm going to keep on doing that, and I will bring you back when I get it all assembled and see what the end result looks like. All right, so I told you guys I'd give you an update. So, the good news is that this is working out really well, and it's nice and solid now.
But, this is still a problem child up here.
And, uh, even after all the glue and stuff, it's still it's still loose.
And, I mean, at this point, the plane's pretty old. I just got off the phone with the guy that um, Mike, he his dad the one that built this.
And, uh, we were discussing some options, and he thinks that the best bet is going to be to remove the foam turtle deck.
And, uh, I guess his dad didn't like to um, build in, uh, with balsa sticks and and formers and stuff cuz he was kind of on the clumsy side and said he put his thumb right through it. So, that's why the top of this thing's all sheeted or all foam and sheeted.
But, you lose some strength in in this area here where it's important. So, uh, I'm going to do basically what I did with the Cougar, and I'm going to cut that off. It's not held in Um he's got some quarter-inch uh tri-stock in the corner uh up underneath there. Uh might be a little bit reinforced towards the tail, but uh Mike said he'd probably be surprised if that was even in there.
And then we're going to use that as a template to make our formers, and we'll probably put like four in here.
You know, I see, you know, one two, three, and then the of course the front.
And then uh some quarter-inch stringers in there, and then resheet it in 16th. So, yeah, I mean I said it earlier in the video that I you know, I I said I'll I'll be surprised if I'm not coming back in here and doing something uh again, and uh I'm not even going to make it off the bench with my recent fix. Now, I haven't put any glue in here, which I could uh you know, drill the holes again and drill throw some real glue down in there to to kind of glue that back together, but um again, it's only a temporary fix.
You know, do you really want to uh risk applying it? Uh number one, the uh you know, it doesn't exist. This is the only example of it. It was a one-off scratch build.
And it flies so dang good that uh I think it's worth going in here and being a little more invasive. Uh I might have some blue covering to rematch the blue, so that way it kind of looks the same when I get done with it, but it'll just be a heck of a lot stronger. So, um I'll bore you with the tearing apart details. I'm just going to go in there and uh find the seam and uh cut it, probably throw my X-ACTO knife down through there, and uh break that turtle deck off.
>> [snorts] >> Um it's already, you know, not attached back here, so and then uh yeah, I'll show you show you how I go about making formers with uh something like this.
Well, that came off a little easier than I expected it to.
You can see where I had my rods drilled through here. You can see I didn't hardly get any glue up in there. I don't know why it didn't go up in there as much as glue as I dropped in there.
Uh But yeah, this is basically just uh um white foam.
And uh sheeted and that looks like uh 3/32, not 16th.
You can set tell he did some time took some time to try to reinforce this area back here, but um we can uh I'm probably going to make some formers.
I'll probably put one back here in the tail.
Cuz I can sneak um might have to maybe the servos.
But yeah, I mean if I put a former back here like in this area and another one, you know, basically where he's got each one of these cross points at here.
And that will stiffen this all all up.
And I'll make them out of basswood. You got to remember this plane flew fine the way it was and this tail section the way it's built is pretty light, so we want to keep weight down to a minimum.
And uh so I'll do that. I'm going to add some reinforcements back here. I might even go in here and do some stick formers.
That might be actually a better idea.
Um I can uh I'll probably it looks like this uh tri-stock is just CA'd in the place, so I'll probably just remove it, too.
And then I can run a run a stick up across and across the top just to just to kind of give this some strength here.
And then you'll see what we do here with the turtle deck.
But uh Yeah, I'm uh I'm usually right with my gut and uh you know, when I say I'm going to be doing something that I don't necessarily want to do right away and I am overly happy that I did this. Now, my cut wasn't super straight. It's hard to find uh where it was cut at or where the splice was. I don't even think there was a splice in here. He probably just you know, sheeted you know.
Oh.
That's definitely uh plywood.
But uh and that's balsa wood. Anyways, I can smooth this out. I can sand across here and make this nice and flat again before I cut my tri stock out and I can use my tri stock as a gauge.
I'll knock these carbon fiber rods off.
Uh no reason to have them in there anymore and then we will start building a proper uh turbo deck.
Yeah.
You can get some strength, but like I said, I want to keep the weight down to a minimum cuz all this is behind the CG and the more weight we at we add to this the um it's going to get tail heavy. So, it flew fine as it is. We'll have to check and I'll have to recheck the balance on on it once all this is done. So, anyways, I'll bring it back here in a little bit.
Well, I'm making some headway and I'm actually get getting some some strength built back into this thing.
I've been busy.
Um anyways, this stuff's just laying in here.
I was fitting it.
We'll get to that in a minute.
But I I went ahead and I added this brace back here because this was kind of weak.
And then um threw some epoxy down in there to reinforce that joint. Um and then I went through and just took some of these half-inch by 1-in sticks that I got. You can see kind of the former I made. This one back here was still a little flexible, so I added that bottom brace.
I did not add the brace up here because it didn't It's pretty strong. I mean, we're pretty close to a former here, so uh you know, there's one right here.
And uh so, I did that, and then I try and then I put the rice stock in across all my gaps here just to give my sheeting something to grab a hold of.
So, um as far as taking the the uh foam block off wasn't really that big of a deal.
Um as you can tell, it was only held on in them four areas.
You can see where my uh where I drilled the holes at for my uh carbon fiber rod. There's hardly any glue in there. That's why that really didn't work.
So, anyways, uh what I did after that is I went ahead and cut all my sheeting out for the for the uh for the bottom here.
I'll get that glued in here in a minute.
Like that.
>> [snorts] >> Of course, I'm just laying this in here, so if my gaps aren't perfect there, they'll they'll work.
I'm just using that triangle to hold that guy up there.
So, [snorts] we'll sheet that. That's uh I believe that's 8 in.
So, plenty strong. And then, um I made uh I used those for template. Front and back. I haven't cut it yet.
And [snorts] uh made those.
Uh that one's fitting pretty nice, and this one I ended up cutting the uh the bottom down bottom off some to equate to my sheeting here. It wasn't there before.
And now that's fitting really nice.
So, uh next step is going to be uh I'm going to go ahead and glue all these bottom sheeting. And I left it off so I could show you guys what I had done on the inside of it.
Just to kind of strengthen that up and not add a lot of weight.
So, the next thing I'm going to do is >> [snorts] >> before I glue these in, um I'm going to put a I'm going to put a stringer in this area and in this or a former in this area and this area.
I'm going to measure it so that way it's kind of equal distance. I don't You don't need more than four. There's really no reason to have more than four.
And then I'll work on uh uh skimming a 16th of an inch off of all these formers so that way my sheeting will uh I can sheet right to it and not add, you know, the 16th of an inch back here.
So, um [snorts] once I get all that done, I'll get these glued in.
Well, no, I won't glue them in yet.
Getting ahead of myself here.
Now, I'm going to put notches in here.
So, I'm going to start with a I got that got some more of that quarter by half and I'm going to use that for my main spline going down the center.
That'll be the main structure point there.
And then I think I got some quarter by quarter something along those lines and I'm just going to add I'll probably do like 1 2 3 and maybe four here. So, probably eight per four eight total of the main stringers.
And then uh we'll go ahead and uh um sheet the whole thing.
Or do I need to sheet the whole thing?
I mean, would it look better if it was open?
It wouldn't add a lot of weight.
Now, I think I'll just go ahead and sheet it just so I got the strength.
That way I'm carrying this load all the way up through here.
Cuz it'll transfer the stringers and the formers, it'll transfer it all up into the front of the fuselage.
This is already pretty strong. It's It's done wiggling. I mean, I'm trying to move it back here and I can't.
So, it's already strong with just a little bit of strength I've added to it, but I'll feel better if I sheet it. Um it'll make it uh look like the original did to begin with. And then uh then we'll talk about what we're going to do for covering cuz I don't think I have any of this uh dark blue left. And I I don't think I have enough of it left to uh cover it. So, we might have to get a little creative with the covering scheme here a little bit, but anyhow, I'll uh I'll get all this installed and uh I'll bring you back and uh show you where I'm at as I progress here. All right, a little more progress here. We uh >> [snorts] >> um like I said, I put this half half [clears throat] by one spline up the center cuz that's where you want your most strength at.
And then um I picked out some of this. I think this is like 1/4 in square.
And you'll see my little lines here.
I just laid it up here and and kind of eyeballed it with what looks good, you know. Of course, wider and then it gets narrower down here.
Um I had decided that I'm not going to sheet this. I'm going to leave it open.
Uh so, with that said, we're going to add another uh 1/2 in by one spline down here to the bottom. So, I'll notch each rib out for that. And that'll give us a good area to get covering to.
So, anyways, I'm going to go ahead and take this back apart again. Now, one problem that I have is that this guy here wants to I mean, I can push that down and glue it. That's going to make that bow a little bit.
And it ain't going to look very good when it's covered.
Um I was trying to not uh cut the 1/4 in or the 1/8 in off of this, but it is making a little bit of a difference.
So, I'm going to go ahead and trim this bottom part down and drop this down.
That'll drop this whole thing down.
Make this line pretty straight.
So, I was trying to edge it upwards because of uh our pilot.
Um He's He's a little little on the tall side, but uh that's all right. It'll work. So, anyways, I'm going to keep going with that. I won't bore you with all the cuts and everything and uh um basically I'm just going to take all these off. I'm going to mark them and cut those out and then I'll repeat the process for the other side.
And then we can finally start putting the turtle deck on here, which won't take long once I get everything cut out.
Oh, don't that look sharp? And it's definitely uh stiffen everything up back here. You can't hard You can't even move the stabilizer anymore like you uh once could.
Um I think we lost a little bit of weight cuz she feels a little lighter back here, but uh I didn't weigh it or nothing.
Probably just going to fly it as is and see if it needs anything.
But uh anyways, what's next? Well, we got to cover this. I'm going to go see if I can't find some scrap uh blue that matches this. I It's going to be interesting to see what uh what we can do with it.
Um I got [clears throat] some paint and I can paint this guy up and uh make it match again and uh so yeah, and then uh all it's left after that is to res- uh put the uh elevator back on.
Like I said, I'm going to add a couple of hinges to that.
Maybe it's the one that broke.
Um that verify that this is 1/4 in balsa wood, so we got plenty of meat back there for hinges.
And yeah, so it's almost done and uh yeah, I'll bring you back when I get her all finished up and we'll uh we'll wrap this up. All right, a little a little bit of an update here.
Um I have uh uh finished installing the uh FrSky receiver in it that I did not get done previously. I just glued a stick in across and zip tied the 900 MHz receiver in there.
I've got [snorts] the single 2.4. I didn't realize that the R6s had uh just a single 2.4 antenna out, but I just shoved it up through the canopy here.
And uh yeah, you can hardly see it right there.
Probably put a little piece of fuel tubing in there just to hold it down.
Uh an exposed antenna is uh in my opinion probably a little bit better of an insulation.
Uh I got the I don't know if I showed that earlier. I got the bear put back in.
Got that all covered.
Looks pretty nice.
When we go to do the restoration or finish covering on this, recovering restoration, we will probably do the same to the front. And just rework that whole front end similar to how we did the back. That'll be in a different uh episode though, of course. So, next thing I got to do and I got a little hole to fix right there. Oh, dang it.
Not a big deal.
Uh whatever. And uh so anyways, I went ahead and put the uh stabilizer back in here. I had not glued this yet, but I just wanted to show where I'm going to move I'm going to move this one. This is the broken ends. I'm going to move it over a little bit. And then I'm going to add two more in here.
And then we'll reglue everything. Uh I really tugged and pulled on the existing hedges where they're at and uh it uh um I couldn't get any of them to move, so pretty happy with that. I am like it's why I'm adding two more to the mix. I would uh hate to lose this. I am not going to do the uh left side yet.
Uh it seems to be holding up just fine and I'll just keep checking it.
I don't want to have to tear it tear it all apart and break something and have to rebuild the stabilizer of the elevator cuz they seem to be glued in well.
And you know, if it lasts all season next year when we do the recover, I'll probably cut all the hinges off anyways, except for this guy.
These will be pretty real.
Anyways, I'm going to get that done and then we'll uh have to get her out to the flying field to charge the battery. She's should [snorts] be pretty much ready to go after all this. So anyways, I think that is I think that is where we are going to finally leave this one off. You see me do it a hundred times. Just going to epoxy them in.
And get them get them secured, make a new push rod. I can't I might look around see if I can find the old one. I might be on the drafting table. Don't matter. Anyways, thank you guys for watching and we will uh we'll see you on the next video.
Later.
Like I started it like a month ago and I think uh
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