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Posted: 2/13/2012 4:46:40 PM EDT
[#1]
Quoted:
Well, I'm thinking about having the frame gussets water-jetted only because the gussets constrain the shape of the frame and they need to be very very accurate. Considered CNC Plasmajet, but I am concerned with the HAZ in the 6061-T6, even though I can get around it by undersizing the holes and oversizing at the edges, but that means manual finish....which would somewhat defeat the point anyways. Anybody know of some one off waterjet places? The gussets nest on a 36x48x.125" plate of 6061-T6. I guess I don't understand. In my experience gussets can be anything and any shape as long as it re-enforces the structural design properly, but I haven't seen your plans. Me thinks you might be "over engineering" certain design functions. BTW, Today I just dropped another $1k on my project - alternator ($400), engine mounts ($450), West System Epoxy ($130), fiberglass tape ($21). I hope you get off much much cheaper than me.... 
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Posted: 2/13/2012 4:50:42 PM EDT
[#2]
In this context, it isn't a traditional gusset like you would have for welding. They go on either side of the square tube truss frame and bolt into place - basically, the gussets act as your cut and drill guides for the tubing to bolt the fuselage together.
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Posted: 2/13/2012 4:54:05 PM EDT
[#3]
Quoted:
Quoted:
Well, I'm thinking about having the frame gussets water-jetted only because the gussets constrain the shape of the frame and they need to be very very accurate. Considered CNC Plasmajet, but I am concerned with the HAZ in the 6061-T6, even though I can get around it by undersizing the holes and oversizing at the edges, but that means manual finish....which would somewhat defeat the point anyways. Anybody know of some one off waterjet places? The gussets nest on a 36x48x.125" plate of 6061-T6. I guess I don't understand. In my experience gussets can be anything and any shape as long as it re-enforces the structural design properly, but I haven't seen your plans. Me thinks you might be "over engineering" certain design functions. BTW, Today I just dropped another $1k on my project - alternator ($400), engine mounts ($450), West System Epoxy ($130), fiberglass tape ($21). I hope you get off much much cheaper than me.... Think bolted bridge truss gussets. Same thing on this project. |
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Posted: 2/13/2012 4:56:03 PM EDT
[#4]
Quoted: Quoted: Quoted: Well, I'm thinking about having the frame gussets water-jetted only because the gussets constrain the shape of the frame and they need to be very very accurate. Considered CNC Plasmajet, but I am concerned with the HAZ in the 6061-T6, even though I can get around it by undersizing the holes and oversizing at the edges, but that means manual finish....which would somewhat defeat the point anyways. Anybody know of some one off waterjet places? The gussets nest on a 36x48x.125" plate of 6061-T6. I guess I don't understand. In my experience gussets can be anything and any shape as long as it re-enforces the structural design properly, but I haven't seen your plans. Me thinks you might be "over engineering" certain design functions. BTW, Today I just dropped another $1k on my project - alternator ($400), engine mounts ($450), West System Epoxy ($130), fiberglass tape ($21). I hope you get off much much cheaper than me.... Think bolted bridge truss gussets. Same thing on this project. And as usual, Aero, you explain what I'm thinking in half the words.  |
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Posted: 2/13/2012 4:56:03 PM EDT
[#5]
Wouldn't TIG welding be better? I preface by saying, I have never built an plane, just chromoly race cars.
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Posted: 2/13/2012 5:05:04 PM EDT
[#6]
Quoted:
Wouldn't TIG welding be better? I preface by saying, I have never built an plane, just chromoly race cars. In this case, no. The bolted assembly will fail more gracefully. This airframe has zero redundancy in the fuselage truss. Plus, the whole point of the exercise was to design an air vehicle that was extraordinarily simply to assemble, at the lowest possible cost in time and tools. The truss is a 2D assembly from 2 X 2 X 0.125 wall square tubes. The prints call for 6063-T6, 6061-T6 is probably easier to find in those dimensions. |
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Posted: 2/13/2012 5:07:42 PM EDT
[#7]
Quoted:
Quoted:
Quoted:
Well, I'm thinking about having the frame gussets water-jetted only because the gussets constrain the shape of the frame and they need to be very very accurate. Considered CNC Plasmajet, but I am concerned with the HAZ in the 6061-T6, even though I can get around it by undersizing the holes and oversizing at the edges, but that means manual finish....which would somewhat defeat the point anyways. Anybody know of some one off waterjet places? The gussets nest on a 36x48x.125" plate of 6061-T6. I guess I don't understand. In my experience gussets can be anything and any shape as long as it re-enforces the structural design properly, but I haven't seen your plans. Me thinks you might be "over engineering" certain design functions. BTW, Today I just dropped another $1k on my project - alternator ($400), engine mounts ($450), West System Epoxy ($130), fiberglass tape ($21). I hope you get off much much cheaper than me.... Think bolted bridge truss gussets. Same thing on this project. Ah! OK, gottcha. |
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Posted: 2/13/2012 5:07:53 PM EDT
[#8]
Quoted:
Quoted:
Wouldn't TIG welding be better? I preface by saying, I have never built an plane, just chromoly race cars. In this case, no. The bolted assembly will fail more gracefully. This airframe has zero redundancy in the fuselage truss. Plus, the whole point of the exercise was to design an air vehicle that was extraordinarily simply to assemble, at the lowest possible cost in time and tools. Thanks, AeroE, that makes sense. |
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Posted: 2/13/2012 5:17:13 PM EDT
[#9]
I tried to upload a sketch, but the server is not working right now. I'll try later.
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Posted: 2/13/2012 5:18:20 PM EDT
[#10]
Quoted: OST |
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Posted: 2/13/2012 5:24:14 PM EDT
[#11]
Gusset Example (Hardware clearance holes and hardware removed for clarity)
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Posted: 2/17/2012 12:55:13 PM EDT
[#12]
So I started a yahoo group for those of us who are trying to modify the Afford-A-Plane to be Part 103 legal.
http://groups.yahoo.com/group/Part_103_Affordaplane/ Should be pretty neat to see what the brainstorming shakes out. |
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