Wes Whitehurst Monarch   Home Page Mats FLYING WINGS

LOG:

December 1, 2000 More testing and building of the dtube tail rib molds. I feel that we will save a lot of weight casting the tail ribs in a mold. The sample we cast weighed .4 of an ounze compared to about 1.5 for the comparable rib using the old method. However the cost of building the molds is very high but hopefully we can use them for other monarchs.

We now have some weight goals: Wings 40 lbs each, Fuselage 50 lbs and fairing and struts 10 lbs. Jim says by his calculations we should do it easily. We will record all of the weights.

	sample dtube. this was a glass/carbon layup done under vacvuum. Igot the vacuum too high and the resin content seemed too low.... and so stiffness suffered. It looks like we should go with two carbon in the dtube, vacuum bagged at about 8-10 inches of vacuum.
	Two new ribs in the molds, just removed from the vacuum bagging, tried a lower pressure of 8-10 inches vacuum. Also I folded back the excess cloth back into the mold to strengthen the sides of the rib. In the background two more plugs for ribs with a coating of epoxy.
	First rib produced... just not quite stiff enough on the eges, so thats when we folded the cloth back into the mold to strengthen it.
	first rib testing for correct dimensions. The new spar is sitting on one of the fiberglass dtubes for comparison

November 30, 2000

	Vacuum bagging the first carbon dtube tail rib nov 29/2000. I'm worried that the one layer of carbon is going to be squeezed to thin to have effective stiffness. We will see tomorrow! The lip was a little weak so it was easily solved by folding the excess cloth around the edge back into the mold.....
	Vacuum bagging a new dtube tail rib mold.

November 28, 2000

	vacuum bagging the dtube carbon/fiberglass shell. The fiberglass was laid in dry then squeeged to minimize resin content, then the carbon was laid in having been wetted out on a plastic sheet. The shell was allowed to cure to the B stage when the bleeder cloth was taken out and the spar/ribs glued in. nov 28/00
	A test sample of the Carbon/fiberglass shell on the dtube.
	Vacuum bagging a sample tail rib mold.

The test samples are listed below. The best weight is the carbon and the 6 oz glass combination. The stiffness is somewhat affected being thinner but still seems acceptible. We will wait until it has fully cured for further evaluation. There were no voids in the heavily vacuum bagged parts using peel ply for the bleeder cloth.

November 27, 2000

We took a break from building from thursday to Saturday. We have decided to make tail rib molds... yes all 54 of them. I have pioneered the process. The molds will be of fiberglass and we will vacuum bag the all carbon ribs.

The Spar was taken from the mold and the weight was 4.75 lbs ( 76 oz.) The fiberglass ones where 6.43 lbs.(102.88 oz)

While the calculations are mine still needing Jim's careful eye, I calculate that the cloth was18.4 oz, the carbon rods 22.36 oz, leaving the resin at 35.2 oz, which means we had too much resin content. We will haveto vacuum bag the spar and all other parts as well.

Today we vacuum bagged a square foot of carbon/carbon as well as a carbon/glass. The resin going into the 6 oz fiberglass was noticeably less. The bagging is at 16 lbs vacuum. Very little resin is coming into the bleeder cloth.

We have a source of AN stainless bolts so that will not be a problem.

Vacuum bagging the carbon/carbon and the carbon/glass. The probe is from a temperature gauge in our oven. Note there is very little resin coming through so our wet out technique is good. Now to see what the finish and weight is!

November 22, 2000.

Sent the plans off again for the third time to see if the color drawing 2016 can be printed. The black and white versions come just fine........

We have finished the first spar. We used two layers of 5.7 oz carbon and ther required carbon rods. The Carbon sheets where prepreged on plastic to get the correct resin content then transferred to the mold. There was some difficulty in getting the last layer of carbon cloth to lay in properly over the carbon rods. We used a heat lamp to huury the cure then when it was setting we pushed the carbon in. It looks very good and we are hoping for a spar of less than 5 lbs.

We had a discussion last night concerning the fiberglass/carbon layup. Wes's main concnern was for wieght and I assured him that there was no weight penalty. With the top layer of 6 oz glass it is very thin compared to the carbon and soaks up very little resin. Wes mentioned that vacuum bagging would no flaws in the surface of the carbon.

Our samples of the Carbon/ fiberglass are very impressive. Jim feels confident that the fuselage can easily be done in that manner. He is a little concerned about the Dtubes because of the different values of shrinkage. We will layup a sample and test it in the heat and cold.

We also discussed the use of stainless for the bolts. Jim will do a study to see how this will work. Wes also mentioned getting a head start on the metal parts. For the moment we are concentrating on the composite parts....see what they weigh then we will have a figure for the metal parts.

	The finished carbon spar with peel ply for the ribs attach points
	Laying in the first piece of carbon cloth. Note the carbon is laid up on a plastic sheet, turned over then placed in the mold. Nov 22, 2000

November 21, 2000.

Your check arrived yesterday afternoon. $2000 thanks

The dtube ribs are out of the molds. We will now drill lightning holes. The weight of the all carbon ribs, two layers was 2 lbs. The fiberglass was 2.3 lbs... but we can eliminate weight from the carbon ones with lighing holes..... hopefully 1.5 lbs.

We do have a chart of weights and I will reproduce that here when I have a moment.

After a number of experiments in carbon layup we have come to a conclusion that to make the Dtubes and fuselage it would be very advantageous to have a a very thin layer of fiberglass cloth over the carbon, eliminating one layer of carbon.. The principle reason for this is to have a much better finish on the craft. The carbon has a hard time laying on the mold and giving a perfect finish. The light fiberglass mates much better to the mold giving a superior finish with very little need to repair or use a lot of filler. There is a weight saving as well, although very small. The dtube still has excellent stiffness with the fiberglass and is certainly structurally correct. If we have a glass layer there will be no problem of any metal to carbon touching on the surface. Our sample is very good!

Please confirm that you would like the fiberglass in the dtube skin and fuselage. Dtube layup and fuselage will start shortly.

The spar will be made of all carbon. Here finish is not important and extra strength of the all carbon is fine. The test sample was excellent.

We have decided to build molds for the rear tail ribs..... yes 54 of them!!! The design and R&D is coming along fine.

I have not got on to the metal parts yet.....but will attend to that shortly.

We have decided to use bushings on all of the fiberglass to carbon fittings.

November 20, 2000. The nose ribs are done. The main spar will commence this week.

	November 20, 2000. Sample spar layup. No problem going around the Carbon square rods! This Twill weave is very good!
	Making up a carbon rib.
	Mat cutting carbon with the pizza cutter

November 15, 2000. The Carbon cloth has arrived and Jim is already making up nose ribs for the dtubes! The spar and fusleage will begin this week.

	The roll of carbon has arrived! And before I got it hung jim was already cutting out nose ribs for the Dtube!
	Jim starting the nose ribs for the dtube! Each rib will have two layers. And to save weight we will have some lightening holes.

Nov 14, 2000. UPS tracking advises us that the roll of carbon is in Ohio!

November 10,2000. The UPS tracking number for the cloth is listed below. We have started the Dtube mold and fuselage mold preparations. Invoices have been prepared for the next deposits.

November 10, 2000. We are now preparing the spar mold and dtube mold. the dtube molds are waxed and pva'd ready for the cloth.

	Dtube ribs ready for cloth
	Scott Beery waxing the spar mold Nov 10, 2000

November 9, 2000. The initial tests of the 5.7 oz twill weave carbon is a real success! The Sample two layer layup is very still and Jim felt that the weight saving would be greater than we had anticipated. The sample dtube rib was fine, and the carbon cloth laid quite easily in the corrugated mold. today we prepare the molds for the dtube ribs, spar and fuselage. The carbon cloth is being shipped.

Top sample piece of two layers of carbon simulating the dtube is better than expected, with unusual stiffness. I had thought we would save money making it a one piece with one weight of 11 oz.. but the two cloth layup was so much stiffer that there is no choice, we need to use two layers

November 7, 2000. Deposited the $2000. Received samples of the carbon cloth. Ordered a full 100 yds of #3572-50-tv after layup tests proved that it was suitable for the glider. Below is a picture of a sample dtube rib, sample corrugated rib material and 1 square foot layup of two layers to test stiffness for the Dtube. We expect the Carbon cloth to arrive early next week. We will proceed with the Dtubes and Fuselage upon receipt of the 40% deposit for each ($885.43 and $1243.33,see above schedule)

Samples of twill weave and plain weave foreground. We decided to use the twill since it is stronger and my form around corners better. Next is the Dtube rib from carbon. I reinforced the center section with a 1 inch carbon strip. Next is the sample corrugated rib layup. Lastly is the 1 foot square, two layes to test stiffness.November 7, 2000

November 06, 2000

Received the Registered letter today with a check for $2000 enclosed. Will confirm everything with Jim before depositing check.

And a note from Dave Shelton

Mat,

Tell Wes that he might be interested in researching a sailplane design
by Dick Schreder. I believe that it's the HP-22 he would be interested in. It
was designed as an amphibious motorglider.

From,
David Shelton

October 30, 2000

mat-cadmium plating is not acceptable ! i have many years experience on a yacht in salt water. 316 grade stainless what i prefer. ref your comment on low mod-carbon for wing ribs. i assume so that it would be easier to work. that flat panel mold is an excellent place to start your vac-bag practice! wouldn't it be better in hi-mod carbon/bagged!? wes the website
for my project is great.!

Marske Answer: OK I will research the availability of Stainless and if we can laser cut the material. Jim feels very strongly about not using a high modulus Carbon for anything. There is no gain in its use for us except to make it brittle. Mat and Dave soared the Monarch G. The CG is back now to about 7 inches and I feel comfortable with it there. See our new page for photos.

October 27, 2000.
The plans minus drawing 2216 where sent off. There seems to be a printing problem with drawing 2216 so we will try again this coming week.It looks like we have settled on the 5.8 oz carbon cloth with a twill weave from Tora. Will order the cloth when we get the deposit for the glider.

October 25, 2000
We have ordered samples of Carbon cloth to do sample layups with. One concern was having the carbon lay up well in the corrugated rib mold. This requires a low modulus carbon, which is also less brittle.

October 25,2000

Wes phoned requesting that I send along the plans. Wes also noted that he wants the lightest monarch possible and would like to fabricate some of the metal parts from Carbon. We discussed some parts in Stainless and with guidance form Wes and Jim we will do that. There was some discussion on laser cutting the stainless as a possibility alhough Wes thought he could do the fabrication himself.

Wes also inquired that there be provision for removing the Struts and having a cantilevered wing. We will consider the possibility. Jim needs to look at the design and see what changes need to be made to the presently designed Dtube.

Wes suggested that he could easily fabricate some of the Carbon tubes to substitute for the Aluminum.

Past photos of the Wes Monarch. August 23, 2001 to Sept 23, 2001

Past photos of the Wes Monarch. July12, 2001 to August 23,, 2001

Past photos of the Wes Monarch. June 11, 2001 to July 11, 2001

Past photos of the Wes Monarch. May 18, 2001 to June 11, 2001

Past photos of the Wes Monarch. Apr 2, 2001 to May 14, 2001

Past photos of the Wes Monarch. Jan 13, 2001 to Mar 27, 2001

Past photos of the Wes Monarch. December15 to Jan 13, 2001

Past photos of the Wes Monarch. Early December 2 to December 18, 2000

Past Photos of the Wes Monarch. October 2000- December 2000

Back to Marske Flying Wings Homepage