From Scratch: Building a Flying Machine

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From Scratch: Building a Flying Machine

Table of Contents:

  1. Introduction
  2. Choosing the Pattern and Template
  3. Selecting the Wood
  4. Customer's Project Requirements
  5. The Airplane: Peat and Pool Air Camper
  6. The Engine: Corvair Engine
  7. The Propeller Design
  8. Mixing and Applying the Glue
  9. The Gluing Process
  10. Using the Press

How a Propeller is Made: Step by Step Guide

Introduction A propeller is an essential component of an aircraft that plays a crucial role in its performance and efficiency. In this three-part series, we will explore the process of how a propeller is made, from selecting the pattern to gluing it all together. This article will provide a comprehensive step-by-step guide for propeller manufacturing, focusing on a specific customer's project involving a Peat and Pool Air Camper airplane powered by a Corvair engine.

Choosing the Pattern and Template Before starting the propeller manufacturing process, it is essential to select the appropriate pattern and template that will suit the customer's specific airplane and engine combination. Our shop houses a collection of around 300 patterns, each designed to cater to different requirements. With careful consideration, we choose a pattern that will be compatible with the customer's needs.

Selecting the Wood The choice of wood for the propeller is crucial, as it directly impacts its strength, durability, and performance. While various types of wood can be used, such as birch and mahogany, our preferred choice is hard white maple due to its exceptional qualities. Maple provides the necessary strength and stability required for propellers, ensuring optimal performance during flight.

Customer's Project Requirements Understanding the customer's project requirements is essential for designing a propeller tailored to their needs. In this specific case, the customer had previously ordered a propeller measuring 66 by 32. However, they experienced lower revolutions per minute (rpm) than desired, prompting them to request a reduction in pitch to enhance engine performance. By lowering the pitch to 66 by 30, the customer can expect an increase in rpm, resulting in improved efficiency.

The Airplane: Peat and Pool Air Camper The Peat and Pool Air Camper is an aircraft with a rich history dating back to its development in 1929. This home-built airplane features a wooden construction, making it ideal for enthusiasts who enjoy the process of building their own aircraft. With nostalgic charm and intricate detailing, the Peat and Pool Air Camper remains a popular choice for aviation enthusiasts.

The Engine: Corvair Engine The engine selected for this particular project is the Corvair engine, which is a horizontally opposed air-cooled six-cylinder engine commonly used in automotive applications. William Wynn offers a conversion kit that enables these car engines to be utilized in aircraft. The versatility of the Corvair engine allows it to run on either aviation fuel or automotive fuel, offering convenience to home-built aircraft owners.

The Propeller Design Designing a propeller that complements the specific aircraft and engine combination is crucial for optimal performance. By understanding the customer's requirements and the characteristics of the Peat and Pool Air Camper, we can tailor the propeller's dimensions, including the hub thickness and pitch, to ensure ideal engine performance and cruising speed.

Mixing and Applying the Glue The glue used for bonding the individual boards of the propeller is a Dapp plastic weld wood resin. While the glue itself does not have a distinct smell, it requires a consistent ambient temperature of 70 degrees or higher for optimal results. In our shop, we use a heater and an enclosed press to maintain the necessary temperature during the gluing process, ensuring a strong and reliable bond.

The Gluing Process Once the boards are cut and sanded to perfection, they are aligned and clamped together using a combination of dowel rods and pins. The center point of the propeller is determined by drilling a hole through each board, allowing for precise alignment. The glued propeller is then placed in the press, applying 75 to 80 psi for a duration of 14 hours. This step is crucial to ensure a solid bond between the laminations.

Using the Press The press, equipped with 18-wheeler airbags, plays a vital role in applying the necessary pressure to the glued propeller assembly. By connecting the air hose and regulating the pressure to 75 to 80 psi, we ensure a consistent and uniform compaction of the laminations. The press expedites the gluing process, allowing for a faster and more efficient propeller production.

Conclusion The manufacturing of a propeller involves a meticulous process that requires attention to detail and precision. From choosing the pattern to applying the glue and using the press, each step contributes to the creation of a reliable and high-performance propeller. By understanding the specific requirements of the customer's aircraft and engine combination, we can deliver a propeller that meets their needs and enhances overall flight performance.

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