X-bracing Loops and Seat Building

First seat frame (outer portion) bent to shape

Last week we prepped the loops for the X-bracing, bent up our first lightweight pilot seat, and made more progress with the bending technique for the Depron foam leading edges for the test wing section.

An existing recumbent seat -- from Lightning Cycle Dynamics, one of our sponsors -- similar to what we are building.

We're using Lightning Carbon Cranks (the lightest integral production carbon fiber cranks available) for the cranks on the DaSH airplane.  Lightning Bikes:  http://www.lightningbikes.com/

A recumbent seat, deconstructed

Prepping for a bend

Making the bend

Outer seat frame surrounded by some test pieces and cross pieces

Clamps and hooks in preparation for Kevlar lashing

Wrapping copper wire around music wire loop before soldering

Soldering the wire loop

Sailing thimbles used to wrap the wire loop around

Finished music wire loops for Kevlar X-bracing test

Finished Kevlar loops for Kevlar X-bracing test

The loops will be lashed here, then the Kevlar X-bracing will loop through the  sailing thimble

Bending the trailing edge of a leading edge panel

Clamping the leading edge panel onto the nose bending tool

Bending the nose radius on the leading edge panel

Bending the final trailing edge of the leading edge panel

Cutting clearance slots for the ribs in a finished panel

Test fitting leading edge panels with tape before final gluing

Nose radius with panel in place, compared to original DAE-11 nose radius for root chord rib

Several panels taped in place

The smaller radius tool (3/4" OD tube) under construction