More pics from Jan. 2011 Prop Build

I just uploaded all the photos from the build of our 10 foot prototype propeller in January 2011.  We'll be building some new 12 foot diameter foam blades in July '12.

The full set of photos are here:  https://picasaweb.google.com/107455148378358982957/Jan2011_DaSH_proto_prop_build

Here is a sampling:

getting started

protractors for aligning ribs

Rib templates and hi-tech sheeting length measure device

gluing the smaller concentric main spars for the thinner tip of the blade

making curved rear spar sections

curved spars complete and dried

carved & sanded blade tip

bending the leading edge sheeting

completed blade, ready for covering -- "Ta-Dah!"

Blade B (blue) 616 grams, Blade A (red), 611 grams

 

Finished Seat Adjuster + test fits of seat

On Sunday we made a rear seat adjuster to replace the shims on the static test rig, then had pilots of different size ranges try it out so we could get a sense for the CG travel needed from shorter to taller pilots.  Here are some photos:

Completed Static Test Rig frame, with rear seat adjusters in place (prop & prop shaft still to be added) 

Below:  Fritz, Grant and Jens try out the seating position

working on a seat adjustment

Shims in front to tilt the seat back a bit to a more comfortable position

More photos at:  http://goo.gl/NwAQc

Alec

Frame for Static Test Rig complete

We finished the frame for the Static Test Rig on Sunday (except for the rear adjustable seat mount, right now we are just shimming it there).

We learned a lot by building it and got a chance to correct some of the frame geometry on the fly.  We also got to try a good range of pilot sizes in the seat.  Even though we don't have the rest of the drivetrain besides the pedals connected, it is still useful to check for fit and CG travel for different-sized pilot candidates.

Now we are working on finishing the parts for the prop shaft, and when they are done we'll be able to mount the prop and try out the whole drivetrain concept.

Here are some photos of the build and the finished frame.

The completed frame 

Static test rig build

This weekend we are working on building a static test rig for the prop.  We have built the basic frame so far.  Tomorrow we will install the seat and more parts of the drivetrain.  Once all the drivetrain parts are done, we should be able to do a static test of our existing 10 foot prop (and later the 12 foot diameter prop planned for the current plane).

I have also included a few photos of the rearranged table setup in the work space.

More photos at:  https://picasaweb.google.com/107455148378358982957/16Jun2012_DaSH_static_rig_build?authkey=Gv1sRgCOb5kMmJrpqD_gE#

Alec

whiteboard sketch of the static test rig design

Static test rig main frame -- internal members, seat and drivetrain to be added

work tables rearranged and assembled