https://ehawk.iolani.org/blog daily 0.75 2022-12-14 https://ehawk.iolani.org/blog/visit-to-rainbow-aviation monthly 0.5 2020-08-30 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595252406410-M8LMTWJQW45BLM6IA16P/Sparky%2B-%2Bemg%2B6.jpg Blog - Visit to Rainbow Aviation - Sparky One of the EMG-6 prototypes https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595252297677-UQQ7F1UHZM01ARWWG7WX/EMG6_prototype.jpg Blog - Visit to Rainbow Aviation - EMG-6 Prototype Prototype to be fitted withthe Polini 250 engine https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595252297733-HKULRG21PWLVJHQTMIOF/rainbow+aviation.jpg Blog - Visit to Rainbow Aviation - Rainbow Aviation The Rainbow Aviation Facility, located in Corning, CA. https://ehawk.iolani.org/blog/cutting-welding-fixtures monthly 0.5 2020-07-20 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595253287626-G3EDILUVTR3UEPCAGNNG/e_hawk_vcarve.jpg Blog - Cutting Welding Fixtures - The path file in VCarve https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595253287125-QK2PDMR9TXWK3UFZMHQI/shopbot+1.jpg Blog - Cutting Welding Fixtures - Our machinists hard at work https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595253288268-5WLWT5XHNBLENCIBTQRW/shopbot.jpg Blog - Cutting Welding Fixtures - Cutting parts for fuselage tooling jig https://ehawk.iolani.org/blog/tjsjikipkk2ocxigsn1wvnav6djrmh monthly 0.5 2022-03-29 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595254079975-P5QMBYYU0DAUL5S223ZV/waterjet1.jpg Blog - Cutting Washers Here's what the layout looks like on OMAX Make after everything has been pathed. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595254080099-E34NQYQSYAJHC1Y20LZB/waterjet2.jpg Blog - Cutting Washers Clamping down the material prior to the cut. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595254080619-56I8CWSJEZ0DWIEBASXP/waterjet3.jpg Blog - Cutting Washers Washers cut with tabs to prevent them from falling through the slats https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595254080810-DCFVLX36BVVOOZTWYEWX/waterjet4.jpg Blog - Cutting Washers Finished product https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595254081395-KSUEAFVWRWGROPSQPBYL/waterjet5.jpg Blog - Cutting Washers Cutting the wing box tooling spacers using the waterjet. https://ehawk.iolani.org/blog/wing-box-fabrication monthly 0.5 2022-03-29 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595261745063-DNGF602BP7CJX7K1PW5X/weld+prep8.jpg Blog - Wing box Fabrication Wing box tooling sides. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595261743977-7AY5J7GKNSCK5K8E0J9H/weld+prep7.jpg Blog - Wing box Fabrication Wing box base tooling with alignment pins. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595261743415-0ULL5LNVNX2P5LYOWN2A/weld+prep6.jpg Blog - Wing box Fabrication Wing box tooling ready to accept tubing. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595261742024-X0IWOFI37UWC1FR30LT3/weld+prep5.jpg Blog - Wing box Fabrication 3D printed temporary inserts act as washers until the real washers can be welded. They allow for the boom mount tubing to be bolted to the jig so that fitment of the other tubes could proceed. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595261741555-VJ5QSA1UPGGWZLWXGXZ3/weld+prep4.jpg Blog - Wing box Fabrication Close-up of the temporary 3D printed insert holding the tube in place for initial tube fitment. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595261740993-E38VGM5DQ7113Y3L8ROL/weld+prep3.jpg Blog - Wing box Fabrication https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595261740347-Z0H34Q7KOXJ5M2Y0JUV9/weld+prep2.jpg Blog - Wing box Fabrication https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595261739848-KQBUNKR6QP9GRZD88QW2/weld+prep1.jpg Blog - Wing box Fabrication The teplating procedure gives a near perfect fit. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595261743223-X6EHLWJVLFCOUWK1QGYL/weld+prep.jpg Blog - Wing box Fabrication Getting close to tack welding everything in position. https://ehawk.iolani.org/blog/custom-3d-printed-drill-tooling monthly 0.5 2022-03-30 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595262149401-6UA71WFOS2OFW829T1SK/drill+jig.jpg Blog - Custom 3D Printed Drill Tooling - CAD rendering of the drilling jigs https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595262149584-MTXTCGP5S648ARESFR17/drill+jig1.jpg Blog - Custom 3D Printed Drill Tooling - Forward Spar mounted within the drilling fixture https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595262150529-Q3Y33F7FTO9CJ69VASGE/drill+jig2.jpg Blog - Custom 3D Printed Drill Tooling - Fixture mounted to the drill press platform https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595262150317-1Q9W5TSDJBVLWS6UKI6L/drill+jig3.jpg Blog - Custom 3D Printed Drill Tooling - Forward Spar ready for drilling https://ehawk.iolani.org/blog/q495utpv2tt6wzfw5u4clb5p84ph8q monthly 0.5 2022-03-30 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595262730695-SX5ESPPBSMFY70F9VBZS/parts2.jpg Blog - Parts Inventory https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595262730168-POZ9FXL6LWV43MIKFZN2/parts.jpg Blog - Parts Inventory https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595262730165-HGAM79WD6F0NTCK9AC9N/parts1.jpg Blog - Parts Inventory https://ehawk.iolani.org/blog/j3tzi04hpzyyr3whd7avfwdg1l40k2 monthly 0.5 2022-03-30 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595263692970-01OQ0SFO5VUUMF0COACK/boom5.jpg Blog - Fuselage Boom Assembly Begins Ready to mate the aft section with the forward section. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595263674064-WAL4BOQWXZL2ON7UOP9P/boom7.jpg Blog - Fuselage Boom Assembly Begins Only a few more cleco fasteners left before we run out and need to reorder. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595263704779-RLYQ9F7HOP155IFF7MVO/boom6.jpg Blog - Fuselage Boom Assembly Begins All hands on deck as the assembly grows. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595263724858-1OPJGE4RDQ6XXMR2H3W5/boom8.jpg Blog - Fuselage Boom Assembly Begins Inside view of the Fuselage Boom. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595263742495-8VR4MG440K08XFJZX81K/boom4.jpg Blog - Fuselage Boom Assembly Begins Forward section of Fuselage Boom is held together with cleco fasteners. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595263581512-9PO1XFBCOGWA8R6SER3I/boom9.jpg Blog - Fuselage Boom Assembly Begins After a long day of hard work you come in the next day only to find the project draped in Christmas lights. They couldn't even wait until after Thanksgiving... The shiny, reflective surface of the 2024 aluminum really make the lights pop. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595263755207-0IV2520QE0WT48UMHCIY/boom.jpg Blog - Fuselage Boom Assembly Begins Here we begin the sub-assembly of the Boom Sides and Internal Stiffeners and the Rear Wing Spar Carry Thru. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595263779815-GXEE37QDZ6QD5DJC6Q2O/boom2.jpg Blog - Fuselage Boom Assembly Begins Noah sets the second official rivet into place. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595263766738-SUSBAH3RKEJDQLL1PGUL/boom1.jpg Blog - Fuselage Boom Assembly Begins Ethan sets the first official rivet in place. https://ehawk.iolani.org/blog/csuz6n7jd9rri4dx37jqa6k5dnnnza monthly 0.5 2022-03-30 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595266554832-FB2NC8ST244460ZJ8HBP/tacked.jpg Blog - Wing box Tacked https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595266562800-XBTNPFGWWMY05ELWF1P1/tacked1.jpg Blog - Wing box Tacked https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595266479707-Y7CZUKHHBABD6WER2I6F/tacked2.jpg Blog - Wing box Tacked https://ehawk.iolani.org/blog/9o49jlnlairsvoeb477ehqyfqqd2ds monthly 0.5 2020-07-22 https://ehawk.iolani.org/blog/es98k2yjxbmmgd9as6wfnhndglpstd monthly 0.5 2022-03-30 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595427466638-XO84IO5PQSG96B1NB0KQ/battery+casd.jpg Blog - Thinking About Batteries CAD rendering of an 18650 lithium battery pack used to power on of our drones. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595427467912-1OZDN0VUSZLBJO3S9E0X/battery+holder.jpg Blog - Thinking About Batteries Cell holders being printed using ABS plastic. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595427467700-YBTM660ZUKADT2NT9NCY/battery+welder.jpg Blog - Thinking About Batteries This is our custom built spot welder. We use a 12V deep-cycle lead acid battery to provide the short 7 millisecond pulses of high current to fuse the nickel strip to the battery terminals. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595427468203-DJPNBTO20CIA3NVTVKV7/battery+welding.jpg Blog - Thinking About Batteries The spot welding process in action. Each terminal receives 2 to 3 welds. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595427466872-FE1056DLGRU9QBN5J18X/battery+cell.jpg Blog - Thinking About Batteries A partially welded pack. The series connections are made after the parallel connections. The nickel strip is 8mm wide by 0.2mm thick. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595427466394-TQWCPT1LTN8R9ZME4K88/batteries1.jpg Blog - Thinking About Batteries A larger 18650 pack comprised of 160 cells. The cells are arranged in a 20S8P configuration for 72V at 27Ah (~2kWh of energy). https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595427466047-T532J9VXBVFYB2394JNI/batteries.jpg Blog - Thinking About Batteries Comparison between pouch cells and cylindrical cells. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595427468726-QWIZV21BR5WEY1XRL656/drone.jpg Blog - Thinking About Batteries This drone was used to test our first 18650 (LG MJ1 cells) battery pack. It hovered for over 45 minutes on this 4S3P 10Ah battery with about 20% reserve energy. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595427468911-6DKWYGZHNEYNDXQCIC77/hexacopter.jpg Blog - Thinking About Batteries This 650mm sized Hexacopter is scheduled to fly with a custom built 24 cell 18650 (Panasonic GA cells) pack in a 6S4P configuration. Click the image to see some of the drones our robotics students have designed, fabricated, and flown. https://ehawk.iolani.org/blog/3xuxdyfte1hw3vxb6d39kka0idv10n monthly 0.5 2022-03-30 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595432618576-GVA7L2V2FV5IJLVVFQ1H/avionics.jpg Blog - E-Hawk Avionics Altimeter prototype comprised of an Arduino Uno, BMP180 Pressure Sensor, 128x64 OLED Display, housed in a 3D-printed enclosure. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595432618755-OXQ473H266QJIFT2R81I/avionics1.jpg Blog - E-Hawk Avionics Main screen shows altitude, vertical speed, and altimeter setting (QNH) that is adjustable using the rotary dial. This prototype is designed to fit in a standard round 2-1/4" cutout. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595432615915-F0SIW026J71QGZPB2UWR/avionics+cad.jpg Blog - E-Hawk Avionics CAD rendering of altimeter. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595432615983-8DIZ4K3UIEUOA6HSF7Y7/avionics+cad1.jpg Blog - E-Hawk Avionics More CAD. We use Onshape for most of our designs. It's been an invaluable tool for our students. It's easy to use, runs in your browser, allows for seamless collaboration, and is free for education. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595432617021-HOPPN0A2EIEMVE22G2TQ/avionics+drawing.jpg Blog - E-Hawk Avionics CAD mechanical drawing of altimeter https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595432617945-STCSHDKGCH6O71MSRTTB/avionics+parts.jpg Blog - E-Hawk Avionics Parts ready for assembly https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595432615649-6KO229APLPXJUUGLQBWX/avionics+board.jpg Blog - E-Hawk Avionics Microcontroller and sensor mounted to perf board. Connectors interfacing with the display and rotary encoder allow for easy assembly/disassembly. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595432615574-04PW55NIF5CGZ6XLD5HA/avionics+board+inside.jpg Blog - E-Hawk Avionics Components installed in 3D-printed housing. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595432617886-1RWV5LHX9L5CVBKCHAUB/avionics+port.jpg Blog - E-Hawk Avionics Rear of unit with USB port for power and programming https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595432616743-X3CA3P5IOTKIXU143WJW/avionics+circuit.jpg Blog - E-Hawk Avionics We will also begin experimenting with an airspeed indicator. Here is a potential pressure sensor that may work. It's originally designed to work with the Pixhawk series of drone flight controllers. https://ehawk.iolani.org/blog/twist-to-level monthly 0.5 2022-03-30 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595433069464-HHTNGX6F3F3HXKZXSFFT/removing+rivets.jpg Blog - Twist to Level - Removing Clecos https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595433069430-GI964U461CJ99IENGV3T/correcting+fuselage+twist.jpg Blog - Twist to Level - Twisting the boom back to level. https://ehawk.iolani.org/blog/a-riveting-experience monthly 0.5 2022-03-30 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595434034306-EM3X2KNODQ5OBPREIF7D/Riveting.jpg Blog - A Riveting Experience https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595433985430-BRKHORLG6D5T8TJ2DDU2/riveting.jpg Blog - A Riveting Experience https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595434034546-B3MJ1VHDHRAB02U268M4/Riveting+2.jpg Blog - A Riveting Experience https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595433984533-PV83W4JRJC14B4IJ6SIV/riveted+fuselage.jpg Blog - A Riveting Experience https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595433984391-DMDAO833WO0TFOFIAX9X/riveted+fuselgae+1.jpg Blog - A Riveting Experience https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595434160559-D3H2Z7BZ1HIYENGTEIWC/Inside%2Bthe%2BRiveted%2BFuselage.jpg Blog - A Riveting Experience https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595434096685-R5ZTS6RXF1BJYQ6L5S8Z/Riveted+Fuselage+2+.jpg Blog - A Riveting Experience https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595434266155-RPLHIOVGX2L4QZL2A9QS/riveted+fuselage2.jpg Blog - A Riveting Experience https://ehawk.iolani.org/blog/dn4u3hxcdkx4t6943h1qnguv98mc69 monthly 0.5 2020-08-30 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598772280628-JZMYBZM4A09QPXUYC607/website.jpg Blog - E-Hawk is now on Instagram and Twitter https://ehawk.iolani.org/blog/aqnsv2sh6neuw6khjdcvlskmmpfd9t monthly 0.5 2022-03-30 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595456784685-IGULRN1LJMF4XI3OP782/hs.jpg Blog - Horizontal Stabilizer Installation Laying out the parts to make sure we have everything to assemble that horizontal stabilizer. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595456784791-G2WYVKB0UY0R80FW3LJS/hs1.jpg Blog - Horizontal Stabilizer Installation Checking the specifications on the AN bolts. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595456785663-UH9MZ00OKEDQOMS78J59/hs2.jpg Blog - Horizontal Stabilizer Installation Grip length and overall length are as expected and within tolerance. Now we know how to decipher the part numbers for the fasteners. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595456786309-AH92A6947K7V4NP44U0G/hs3.jpg Blog - Horizontal Stabilizer Installation The left and right horizontal stabilizers are starting to take form. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595456786286-B0CO13DJ3MES0B82ULA2/hs4.jpg Blog - Horizontal Stabilizer Installation https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595456787483-9KIGNCB2QK3FF3P2OC2D/hs5.jpg Blog - Horizontal Stabilizer Installation Starting to drill the holes in the inboard and mid rib tubes. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595456787213-V3YFINK7IPYT9CWBL2HH/hs6.jpg Blog - Horizontal Stabilizer Installation We designed and 3D printed another flanged collar to ensure that we hit top dead center and stay lined up all the way through. The set screws prevent the tube from rotating during the drilling process. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595456787787-953RXZQSZ3TIWIKDHM8W/hs7.jpg Blog - Horizontal Stabilizer Installation The left side mostly complete except for the sheet metal ribs. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595456788101-6NI820M5647WZC8VK8I1/hs8.jpg Blog - Horizontal Stabilizer Installation Leading edge of horizontal stabilizer and inboard rib tube interface. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595456788376-DZYD15G462SXUXKCGQRM/hs9.jpg Blog - Horizontal Stabilizer Installation Leading edge of horizontal stabilizer and inboard rib tube interface. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595457233752-R7NAMXGY6N9J4NSQSW2I/hs10.jpg Blog - Horizontal Stabilizer Installation https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595457233687-Z3VUNSBRIK8KVD382I68/hs11.jpg Blog - Horizontal Stabilizer Installation https://ehawk.iolani.org/blog/rv2zzwqrgo98xulesx2ujjsxcgo3nl monthly 0.5 2022-03-30 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595457900146-97KCPJ7682MJ7GRS06GW/posing+in+front+of+ehawk.jpg Blog - “Rudder You Doing Today?” https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595457900267-5YB6A1IDUWVXVLX0X025/posing+in+front+of+sullivan.jpg Blog - “Rudder You Doing Today?” https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595458008797-GTN5RZPJNM4LO87F53TA/rudder2.jpg Blog - “Rudder You Doing Today?” https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595458010336-RWJZTO2UJ3NUMHSLM83Y/rudder6.jpg Blog - “Rudder You Doing Today?” https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595458009262-OZTF0P5W9D0N4N8LUR6S/rudder3.jpg Blog - “Rudder You Doing Today?” https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595458007894-MZJSW2N04HUBVYNQNAO6/rudder1.jpg Blog - “Rudder You Doing Today?” https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595467708659-B6G92JDJWJTHGPU3291N/rudder12.JPG Blog - “Rudder You Doing Today?” https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595458011275-BBWXT7LDP0XX51DC7BWZ/rudder8.jpg Blog - “Rudder You Doing Today?” https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595458011150-A3SRG5CNU0WEE0V3XEU1/rudder7.jpg Blog - “Rudder You Doing Today?” https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595458011902-8FHEB5MLNIJSLVC6PLZG/rudder9.jpg Blog - “Rudder You Doing Today?” https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595458012039-DM5IIGYAJ95ZDQGCCW8P/rudder10.jpg Blog - “Rudder You Doing Today?” https://ehawk.iolani.org/blog/hpv8k48ha63x6xspmczyiwwtdyvdyg monthly 0.5 2022-03-30 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595467993041-ZWXC34PGAU7OMJO8UYHP/Designing+Die.jpg Blog - 3D Printing Die CAD model of the tooling die. The screw holes allow for mounting if necessary. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595467992674-PGNAGEM72Z0S6VVH1NKN/3D+Printing+Die.jpg Blog - 3D Printing Die Printing on our Makergear2 with PLA and 70% infill. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595467993928-24I2R7M8T61PEFZA9CJL/Die+Clamped+to+Rudder+rib+%237.jpg Blog - 3D Printing Die Rib clamped to die, ready for bending. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595467992668-IZIUJY7XKMD5IDK0KF7F/Bending+the+Flanges.jpg Blog - 3D Printing Die Flanges bent further to perpendicular https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595467994060-497P08BOCKIKUYZVF3Y7/Rudder+Rib+%237+Installed.jpg Blog - 3D Printing Die The finished part installed in the rudder. https://ehawk.iolani.org/blog/elevator-and-lift-struts monthly 0.5 2022-03-30 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596397669498-MWWIHQJOZBTVU5W0HN48/elevator.jpg Blog - Elevator and Lift Struts Assembled left and right elevators ready to be hinged onto horizontal stabilizer. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596397673302-P5NM6R30HWYT6QJ14E45/elevator08.jpg Blog - Elevator and Lift Struts Drilling holes for the rivets that will fasten the strut to the insert. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596397669381-XA3JPHL0JEC1ER4LUM7X/elevator1.jpg Blog - Elevator and Lift Struts The lift strut extrusion is being measured for correct length. The streamlined strut material had a circular pocket that will accept a threaded insert on each side. Fork bolts will screw into the inserts. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596397676016-G4Z0O7MYKHVHNH9H4IYX/elevator15.jpg Blog - Elevator and Lift Struts Cutting the strut extrusion to length. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596397674132-8XUVD9V7BK1WIQG38FJE/elevator11.jpg Blog - Elevator and Lift Struts Using the calipers to measure and scribe where the holes for the threaded inserts will be drilled. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596397674840-HGRNIG6V1LS318C9YJ6E/elevator12.jpg Blog - Elevator and Lift Struts Three 1/8" stainless rivets are placed on each side of the strut per insert. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596397674903-Z4HT5I5UFT5BFL4K6V3G/elevator13.jpg Blog - Elevator and Lift Struts Attaching the bottom end of the horizontal stabilizer lift strut to the bottom of the trailing edge of the vertical stabilizer using a fork bolt to eye bolt connection. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596397672236-6LDBRN97SB7D127YGSST/elevator07.jpg Blog - Elevator and Lift Struts And the same for the right lift strut. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596397672124-CPLQH7E9GF1HGD9ZH5C8/elevator06.jpg Blog - Elevator and Lift Struts Right elevator being attached to horizontal stabilizer. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596397670788-HIN1KGO9QDSCJF8C9NV3/elevator02.jpg Blog - Elevator and Lift Struts Top of the lift struts being attached. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596397670929-YHD8RXPKB2I1RU4CSBN3/elevator3.jpg Blog - Elevator and Lift Struts The finished product. The tail section is now complete and the next task will be to cover the surfaces of the tail feathers. We are currently researching Oratex which is a fabric that is easy to apply and requires no paint or other protective coatings. https://ehawk.iolani.org/blog/more-fuselage-frame monthly 0.5 2022-04-04 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596792832207-CY74OGRA0XICXNCQ9LDX/Fuselage1.jpeg Blog - More Fuselage Frame Deburring some the bolt holes that will attach the nose skid to the fuselage frame. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596792840875-XY2FLORARRD6UIX40RWW/Fuselage2.jpg Blog - More Fuselage Frame Nose skid saddle being prepped for welding. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596792850304-QDTNI73V69TSFTT2S41P/Fuselage3.jpeg Blog - More Fuselage Frame This is the rudder bar that the rudder pedals will pivot on. The lower keel tube is clamped into place so that we can drill through both parts for guaranteed alignment. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596792856619-56B26F0VQW8SK2MORPYY/Fuselage4.jpeg Blog - More Fuselage Frame Rudder pedal bar is being positioned with respect to the lower keel tube. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596792862349-AOHY0BQFUKFPTZWSMYX1/Fuselage5.jpeg Blog - More Fuselage Frame The left-side seat to lower keel tube is positioned and tacked into place on the saddle. The right side is next to be installed. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596792886635-3ZOJNQKAVOP7QZPD8D2X/Fuselage6.jpeg Blog - More Fuselage Frame The forward portion of the fuselage frame is mostly complete. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596792950691-QHUGLQQWSVQEOJTW4870/Fuselage7.jpeg Blog - More Fuselage Frame Final drilling to fully attach the keel tube to the fuselage frame. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596792957731-UGXMPIK6EDYK4XP3TNE4/Fuselage8.jpeg Blog - More Fuselage Frame Here we are taking some measurements for where the control stick will mount. With the basic structure of the fuselage frame mostly complete, it's time to start adding all of the structure for flight control actuation. In our next post we will cover the first part of the flight control system. https://ehawk.iolani.org/blog/to-the-paint-hangar monthly 0.5 2022-04-04 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596794623071-B2BQKJX9QSMNK3MP8XC6/Paint6.jpeg Blog - To The Paint Hangar https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596794622416-OSD0GQTZG7KJKGOAS456/Paint5.jpeg Blog - To The Paint Hangar https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596794624833-6XNZPU0E3RC19WFN1A3E/Paint4.jpeg Blog - To The Paint Hangar https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596794625191-KCR8XXSOA0IJGQJ1P7AK/Paint3.jpeg Blog - To The Paint Hangar https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596794626928-AFW5P4GPDGQ919UYZYT9/Paint2.jpeg Blog - To The Paint Hangar https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596794627260-1VXCNGYZBA7ADT40VFVD/Paint+1.jpeg Blog - To The Paint Hangar https://ehawk.iolani.org/blog/tog33vxwx4hj99z18vyyvi2a926alh monthly 0.5 2022-04-04 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596795512968-1250363E6MFQG0YND0SO/FlightControl16.jpeg Blog - Flight Controls Fitting the torque tube standoffs into position just prior to welding. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596795513520-UBYXUH170J9WA4RI4UD8/FlightControl15.jpeg Blog - Flight Controls Holding the parts in place for tacking. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596795515295-IHUK3ZAIJPUJ7MOOWYUU/FlightControl14.jpeg Blog - Flight Controls Elevator control stick torque tube. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596795515972-INQM2CB1VUYOFRADKZ1K/FlightControl13.jpeg Blog - Flight Controls Aft bulkhead control mount standoffs are fitted and clamped into place for tack welding. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596795517872-21P8C8057LGJJ1QKW024/FlightControl12.jpeg Blog - Flight Controls Checking the drawings for the control stick. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596795518547-8ZKQNNJNDYMEEXO0QJLD/FlightControl11.jpeg Blog - Flight Controls The wire brush will remove the burr from the control stick tube prior to welding. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596795521323-KX3AMXOJKU8RZHUEP9NC/FlightControl10.jpeg Blog - Flight Controls Drilling holes in the control stick using a 3D printed drill fixture. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596795521562-SDIIOH97UF7MJNQEBEXX/FlightControl9.jpeg Blog - Flight Controls Locating holes to be drilled in control stick. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596795524056-U1ELYWDM1IAZAJ41I3PA/FlightControl8.jpeg Blog - Flight Controls Aileron torque tube bearing being prepped for welding. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596795524170-ESP4EKEEP887J07LBY2Q/FlightControl7.jpeg Blog - Flight Controls Completed aileron torque tube bearing with nylon bushings inserted. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596795526685-5IKPXUNJHXHIOQQT9NEO/FlightControl6.jpeg Blog - Flight Controls Enlarging and deburring the holes in the elevator bellcrank. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596795526566-3LGIMXZL3FUP8WZDMTN7/FlightControl5.jpeg Blog - Flight Controls Elevator control stick torque tube installed with control stick and elevator control horn attached. The 3D printed saddles are temporary until we machine the the real parts from aluminum. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596795529298-UVCDPFL728HOZD3E7O9I/FlightControl4.jpeg Blog - Flight Controls Another view of the control stick mechanism. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596795529297-83A26MTQNWFZ6Q6PHFES/FlightControl3.jpeg Blog - Flight Controls We 3D printed a temporary u-joint from red TPU flexible filament to couple the control stick with the aileron torque tube. This way we can test the movement of the system. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596795531856-O6IJACJSW4R6RS27XU50/FlightControl2.jpeg Blog - Flight Controls The aft torque tube is shown here with elevator bellcrank and aileron bellcrank in place. The pulleys for the rudder cable are also installed. The red parts are temporary 3D printed shaft collars. The real collars will be machined from aluminum. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596795531527-TL228DC6522GJHEJ5A1D/FlightControl1.jpeg Blog - Flight Controls https://ehawk.iolani.org/blog/1fcpw6289wk50gsxqkuod01tlnqr4s monthly 0.5 2022-04-04 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596798394876-M0KJ1LOR3Q4WDLG2UW31/Rudder21.jpg Blog - Rudder Control Machining the rudder pedal bushings from 2024 aluminum round stock. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596798394775-I3RJ15H5I8UCZYPTQYU2/Rudder20.jpg Blog - Rudder Control Drilling out the center to a size large enough to accept the cutting tool. Then we begin to enlarge the inner diameter to the correct dimension. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596798396553-JKYQDLL3CXFP7VXXS2DJ/Rudder19.jpg Blog - Rudder Control The bushing meets tolerance and is ready to be cutoff. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596798396555-M51LCP9Y3ODS157G86MF/Rudder18.jpg Blog - Rudder Control The 4 required bushings have been completed and are then test fit on the 4130 steel tube. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596798396864-QJH6FI43UZ5H26B7O7KY/Rudder17.jpg Blog - Rudder Control We created a CAD model of the EMG-6 designed rudder pedal with the bushings to ensure that everything would fit together. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596798397867-QC1BIL0X94Q5RCNYJU1P/Rudder16.jpeg Blog - Rudder Control We then 3D printed the rudder pedals and installed them on the fuselage frame to test their function. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596798397211-L0G7J6TYEQ04YQ7PXXJM/Rudder15.jpg Blog - Rudder Control Following the functional test of the originally designed rudder pedals we decided to make some modifications and designed a custom E-Hawk pedal that would later be fabricated from aluminum. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596798397969-UYCTHYO8SHWGKFM4GZXV/Rudder14.jpg Blog - Rudder Control Engineering drawing for our custom pedal with bending parameters. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596798400510-S8SQ5NK8HN9FIJJB3M4N/Rudder13.jpeg Blog - Rudder Control The flat panel of the rudder pedal cut on the waterjet from 1/8" 6061 aluminum. The part then gets annealed and sent to the hydraulic press for bending. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596798400324-CZEX0UZLU3MVSOF69XFY/Rudder12.jpeg Blog - Rudder Control After bending is complete we polish the rudder pedals with fine grit sand paper and install onto aircraft. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596798402700-8UJ6KMFEDVDZND3ZE243/Rudder11.jpeg Blog - Rudder Control Rudder cables are prepared by terminating the end with stainless steel cable thimbles and tin plated sleeves. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596798402710-LWX0N3Z7OBTI8BIDTF3D/Rudder10.jpeg Blog - Rudder Control Once all the parts are aligned we swage the sleeve onto the cable. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596798405147-KZZVRIKOJN8XEP502HWT/Rudder9.jpeg Blog - Rudder Control The completed end of the cable is then attached to the forward rudder control horn via a shackle. A second sleeve will be swaged onto the cable for redundancy. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596798405669-6SFD0R3W6GG7MOO7FP61/Rudder8.jpeg Blog - Rudder Control Time to route the cable from the control horn around the lower fuselage frame pulley, up through the tailboom pulley, and then down the length of the boom to the aft rudder control horn. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596798407017-7S8L87BTOZ9RNXXYH3WD/Rudder7.jpeg Blog - Rudder Control Rudder control cable routed along the lower pulley. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596798408005-PGNZ58TV1G943JHZ84NJ/Rudder6.jpeg Blog - Rudder Control Rudder cable running along the upper pulley. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596798409185-TMFOQF3Q3VWWCDPT6CGV/Rudder5.jpeg Blog - Rudder Control Rudder cable exiting the tail boom and making its way to the rudder. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596798410646-KDCAS1IECJ7LQSNCNI7T/Rudder4.jpeg Blog - Rudder Control Attaching the rudder control cable to the rudder control horn. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596798410526-7L8B9ZQGBXG866YZ6IOQ/Rudder3.jpeg Blog - Rudder Control The control cable is temporarily secured to the rudder control horn. We will wait to permanently terminate via a swage. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596798411611-5LTSTZ6RC3JA3YMJB933/Rudder2.jpeg Blog - Rudder Control For now we hold the cable in place using a 3D printed clamp that we can tighten with a wing nut. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596798412700-9YIYD8RUW7X1R4WH2TOT/Rudder1.jpeg Blog - Rudder Control Coiling up the excess of cable from the right side. Next we duplicate our efforts on the left. https://ehawk.iolani.org/blog/landing-gear monthly 0.5 2022-04-04 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596801243115-AV9TYTA60Z1DB3GY1WZS/Landing22.jpg Blog - Landing Gear https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596801243103-EBVD5348KQFRQEXLEBAB/Landing21.jpeg Blog - Landing Gear The 4130 tubing for the gear leg is cut, coped, and placed into the welding jig. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596801244206-265YUQVQ34TO8KLN5XOM/Landing20.jpeg Blog - Landing Gear The gear leg spreader is tack welded into place. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596801244441-8R5DGIYDTBZSNWV25JH0/Landing19.jpeg Blog - Landing Gear Both left and right gear legs partially welded. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596801245380-7J8BNJIJ44E2PIIRWT30/Landing18.jpeg Blog - Landing Gear Tabs that provide structural integrity to the landing leg attach point are tack welded into place. We will then heat the tab via oxy-acetylene torch and wrap it around the axle and finish welding the seams shut. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596801245504-1F51J88P7JTHP0Q3SVCS/Landing17.jpeg Blog - Landing Gear The wheel axle tube is temporarily slid into place to check the fit. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596801246694-GDOFAIYP3OXN7DC3XXGJ/Landing16.jpeg Blog - Landing Gear Aft gear attach tabs have been cut on the water jet are fit checked prior to welding. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596801246929-QRR69M8OU8W6FOGBR0GD/Landing15.jpeg Blog - Landing Gear Forward gear tabs will require some grinding to close the gap prior to welding. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596801247600-JTU3YSZ4UMNBOT8WRJN3/Landing14.jpeg Blog - Landing Gear The gear leg bottom mount will be the attach point for the strut. It's cut from 1/4" 4130 steel. It's clamped into place to ensure alignment with the upper gear strut mount. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596801248456-RSZFC72OGADNKFLS0ZMQ/Landing13.jpeg Blog - Landing Gear Here is the upper gear strut mount clamped for alignment. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596801249419-SHUOCPW09OQBN77MJ4WC/Landing12.jpeg Blog - Landing Gear The strut mounts are now in position and will be permanently welded into place. Note the wheel axle runs all the way from the left leg to the right to ensure that the wheels will run parallel. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596801249942-O22Y4860M6O9EKDVE3K0/Landing11.jpg Blog - Landing Gear Right angle grinder is used to cut the wheel axle tube to the correct length. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596801250789-HZP8FD5VOWLR9TPDYCLW/Landing10.jpg Blog - Landing Gear Time to start working on the struts. These are spring holders. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596801251506-3V6GY5V9VADI8JAKIWQV/Landing9.jpeg Blog - Landing Gear Using the mill to cut slots into the strut spring tube. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596801251713-C3DTMFWEYCO28CM0G4SE/Landing8.jpeg Blog - Landing Gear One side is almost done. The tube will be flipped and a matching slot will be milled on the opposite side. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596801254021-0R0P34VARNVU7M11WV9Q/Landing7.jpeg Blog - Landing Gear Checking to make sure that the slots were milled correctly and that the plunger slides freely. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596801254555-2VI9811OQ2S69ESD7AM4/Landing6.jpeg Blog - Landing Gear We start to install the landing gear sub-assemblies onto the fuselage frame. The gear legs go on first. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596801255883-O9U26FJP4R2NCN9PHTZR/Landing5.jpeg Blog - Landing Gear The struts are temporarily compressed using clamps which makes it possible to attach both the top and bottom bolts through the strut mounts. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596801255672-6YL7VVQ22OPA6HL7I4R1/Landing4.jpeg Blog - Landing Gear Left side gear is complete. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596801256757-9A0AU6BCSJ707PLC4G2A/Landing3.jpeg Blog - Landing Gear Front view of gear. Right side strut is up next. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596801257486-2HX1NJDDU0K0SJZ7IFTH/Landing2.jpeg Blog - Landing Gear Both sides are on with the gear supporting the fuselage frame for the first time. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596801257975-LEXEPVE6G7HKMYT4WQLO/Landing1.jpeg Blog - Landing Gear Union break. https://ehawk.iolani.org/blog/c6ej7okk4iuwa4an1un16v8tvcdm7x monthly 0.5 2022-04-29 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596948514752-H1Q6OUKGZ4LQLQUQM19X/prop15.jpeg Blog - The Prop The prop kit included the blades, 2-part hub with flange plate, bolts and washers, digital protractor for adjusting pitch, and an instruction manual. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596948384204-YA3DIQBAQ89YC1GZ0GI4/peop3.jpg Blog - The Prop This is the CAD model of the adapter plate. It allows us to attach the hub which has a 6M8d75 bolt pattern (common on Rotax 2-strokes) to our electric motor which has a 6M6d50 pattern. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596948382429-S0700BC4ZBT2P4YYPS5R/prop7.jpeg Blog - The Prop Forward view of the adapter. The M6 holes are counterbored so that the hub can lie flush to the plate. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596948382521-ROV50EDZBMHXF3SWQS59/prop8.jpeg Blog - The Prop All of the components, less the blades, are assembled prior to fastening to motor. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596948384729-GCGZ8TGPV102PWR1P5X8/prop4.jpg Blog - The Prop Screenshot of the CNC path required for machining the prop adapter. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596948383658-K85LVTR0V7D4RKG3RFJZ/prop5.jpeg Blog - The Prop We used our X-Carve CNC router to machine the adapter plate from 1/2" 6061 aluminum stock. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596948381505-3JLCZUHG8W6PRACE21IG/prop10.jpeg Blog - The Prop The first step is to insert the M8 bolts from the front and then mount the adapter to the motor using the M6 socket head cap screws. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596948380165-COCABDFMJI0Y3IYAU7JS/prop12.jpeg Blog - The Prop Carbon fiber goodness. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596948381296-2JHBMPQOV8JU3Y8QCLWA/prop11.jpeg Blog - The Prop The pitch of the blades is set and the propeller is mounted with all fasteners torqued per spec. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596948489934-WZUR908C3BI6TEG0K8PO/prop2.jpeg Blog - The Prop The full up weight of the prop assembly, including the adapter plate. The only parts missing from this weigh-in are the are 6 M6x24mm socket head cap screws. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596948380251-SE4LB4U8SRKQVAG4ZLP9/prop13.jpeg Blog - The Prop A view looking aft. Next step is a prop run-up. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596948450217-BXOB4MSH7ITT2O3ZZ8O9/prop14.jpeg Blog - The Prop Rear view of the fully assembled and mounted propeller. https://ehawk.iolani.org/blog/16eyo4ggtl1kkfkevyb02xpoqlue1o monthly 0.5 2020-08-09 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596948848567-GKDWRNS4FOX5WXZNTHQG/test.jpg Blog - Motor Run-Up With Prop Data logged from a test run. Investigation as to why the current values are so noisy are underway. https://ehawk.iolani.org/blog/zcvosm7ow0nsusdt6wy0u02i5l9nia monthly 0.5 2020-08-09 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596948937953-DCVJ5DI8VTY2EA1E8QX2/image-asset.jpeg Blog - Indoor Taxi Test https://ehawk.iolani.org/blog/q9fwvu9e6pg1lc8szz4w769kb8ssqa monthly 0.5 2022-04-29 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596949098169-R5XPEJDBQN3N31AZ4BVE/wheel11.jpeg Blog - Tail Wheel The upper tail wheel control arm is linked to the rudder control arm via springs. It is through this linkage that the rudder pedals actuate the tail wheel. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596949098052-L4ITI5P8QSCT71B0A8U7/wheel10.jpeg Blog - Tail Wheel The completed tail wheel assembly installed on the aircraft. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596949099375-5T5ZTBGUXKZAP9O5KWFN/wheel9.jpg Blog - Tail Wheel The completed parts with a coat of primer. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596949099506-BF4OXBD7MX8SPOEQLXYU/wheel8.jpg Blog - Tail Wheel The partially completed assembly is test fit to the tail skid tube prior to welding the sleeve bearing standoff tube to the tail skid connector tube. The flanged bronze bearings will allow for smooth rotation during steering. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596949100786-8CW313VCQZDBBEWWIFSO/wheel7.jpeg Blog - Tail Wheel The next step is to weld the upper and lower control arms to the control arm tube. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596949100919-O7EVHQJ5G40G3TPQTBV7/wheel6.jpeg Blog - Tail Wheel The tail wheel arms are welded to the control arm aft tube. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596949102395-8WZ61URC4KZIIT1ASK6W/wheel5.jpeg Blog - Tail Wheel The parts are temporarily held together using fasteners and clamps prior to welding. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596949102648-H77W6VHXQCBCPZ70JTAV/wheel+4.jpeg Blog - Tail Wheel Just off the waterjet we have the two tail wheel arms and the upper and lower control arms cut from 0.09" 4130 steel. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596949103899-SC600XBJAPCQAXM9H35I/wheel3.jpg Blog - Tail Wheel Tailwheel parts layout on the waterjet. Twelve minutes and they are done. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596949103763-P6VIEV8XV0EOUOGG9Z3R/wheel2.jpg Blog - Tail Wheel This is the original tail wheel assembly design. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596949104710-3JS3KLB073FE1WPR74JC/wheel1.jpg Blog - Tail Wheel This drawing highlights the details of our design. All of the custom parts are 4130 cromoly steel that are welded together. The balance of the parts include AN fasteners and a couple of flanged bronze bushings used as bearings. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596949104715-DHNXFZFW860QUBO27B1Q/wheel.jpg Blog - Tail Wheel This is the CAD rendering of our modified steeralble tail wheel. https://ehawk.iolani.org/blog/j0jquch8ag5apyvktjkzgp40nouvcs monthly 0.5 2022-04-29 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596950742978-Q5L2PE8OW3OZKNUSUQOL/seat21.jpg Blog - The Seat The first step consisted of clamping in some scrap pieces of plywood to act as a quick mock-up for the seat. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596950742978-9K3U1BUSXYNG1N8YBFQ2/seat20.jpg Blog - The Seat The seat mock-up gave us the opportunity to perform some basic checks for fit and comfort. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596950745555-37M9WXN0A49ZP8LDRT0T/seat19.jpg Blog - The Seat Once the fit check was complete it was time to install the tubular structure that would support the seat back plate. The seat bottom plate would be supported by the existing structure that is part of the fuselage frame. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596950745669-S1GTCSTTUJ7AD7WHQLID/seat17.jpg Blog - The Seat The seat backrest supports are installed. We used generic aluminum tube connectors to attach 1" aluminum tubing to the fuselage frame. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596950747690-JC6RXHOM0L5FKX36H077/seat18.jpg Blog - The Seat Since the tube diameter of the section of the fuselage frame we were connecting to was 3/4" we had to fabricate some sleeves to fill the gap. The sleeves are 3D printed from TPU flexible filament. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596950747997-W99J2Y58N7TEUN1V1TP1/seat16.jpg Blog - The Seat Taking measurements for what will become the seat plate. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596950749261-D7BTEXLJVFZ7LHNZ5H67/seat15.jpg Blog - The Seat The measurements are transferred to CAD as we begin to design the bottom seat plate. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596950748826-B1O8O2KBTEV8PVPGB1UX/seat14.jpg Blog - The Seat Rendering of what the bottom and back seat plates will look like when placed in the fuselage frame. The plates will be cut on the waterjet from 1/16" aluminum. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596950751346-JMIXV9OQ0Z4WHQ5OKELI/seat13.jpg Blog - The Seat The finished bottom seat plate is fitted into position prior to drilling the rivet holes that will fasten it to the seat tabs on the fuselage frame. When you design the parts yourself you get to inconspicuously slip your names into the part. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596950752394-X6H6UYSP5OGMNLNVYYKI/seat12.jpg Blog - The Seat Riveting the seat plate into place. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596950753685-UCCC4HKJJOCF7HE1YKLQ/seat11.jpg Blog - The Seat Installing the supports that will hold the back plate in place. "Something doesn't look right". https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596950755848-OUCD7N4HLQH7KATSDD3K/seat9.jpg Blog - The Seat Taking measurements for the custom seat cushion that will be produced in-house. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596950756689-V0JSESZDL6ITTPEHENAP/seat8.jpg Blog - The Seat We decided to go with 2" thick, high-density polyurethane foam for the cushion. Here we mark the foam for cutting. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596950757418-KQCWGYTXH5PWF5K5STMU/seat7.jpg Blog - The Seat We are using our in-house designed a built hot wire foam cutter. Using a 2x4 as a fence we get a perfect cut. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596950759031-QKJT6AB9B9P4URRHS363/seat6.jpg Blog - The Seat The seat cushion covers are sewn using a water repellent canvas type fabric. The short edge of the cover includes a zipper so that we can remove the foam for cleaning or replacement. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596950759337-3ZZBOU4H46FAYP7MMO7A/seat5.jpg Blog - The Seat Foam being inserted into the cover. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596950761735-DC54WQZRKV2H71Y6FFEP/seat4.jpg Blog - The Seat The seat bottom and seat back plates are lined with velcro which will hold the seat cushions in place. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596950762021-42EKVY4TQ8YIHRUWA5NC/seat3.jpg Blog - The Seat Installation of seat cushions. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596950764101-68QKJWRRRPIMPN60MX9N/seat2.jpg Blog - The Seat Now that the seat cushions are complete, we can do a fit check and cut the seat belt to length. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596950765021-C9LMMLX5DSJNMYZOVYXY/seat1.jpg Blog - The Seat The completed seat with seat belt. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596950766189-F39CYB81ARRRZSY5JUYW/seat.jpg Blog - The Seat Aft view of the seat. The only thing remaining is to attach the lower seat belt to the fuselage frame. https://ehawk.iolani.org/blog/oa0c3z1newmcs3tpidedb1wjr77n3t monthly 0.5 2022-04-29 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598507693853-MUW1P6HPUS05W907A5I8/wing.jpg Blog - Wings https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597010419325-DA8330518HK0NAZY93JA/w2.jpg Blog - Wings Cutting the tubing that will make up the drag struts. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597010419418-XZ4EMBLNG558FWMGIPFZ/w3.jpg Blog - Wings Double checking the length of one of the compression struts. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597010417354-EEKIX11MEXHJXND4PL1R/w4.jpg Blog - Wings The crew works on tightening all of the fasteners that will attach the compression and drag struts to the leading and trailing wing spars. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597010416632-PQSX5MXIGY6VEUIN9YD0/w5.jpg Blog - Wings The lift strut attach fitting has been cut, heated and bent, and placed in position for welding to the fuselage frame. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597010415219-1CPDJ5L8G927USON5QOI/w6.jpg Blog - Wings Lift strut attach fitting welded to fuselage frame. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597010415013-CTP5IB9IDZ91GZXX353W/w7.jpg Blog - Wings Lift strut fittings fabricated and painted. These will be inserted into the lower ends of the forward lift struts to make the connection to the fuselage frame. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597010413249-RSKLSNQHHAA1OWQFJ3ZY/w8.jpg Blog - Wings Lift strut attach fitting bolted to fuselage frame. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597010413448-VQL7325R4CGMJ94SC9S6/w9.jpg Blog - Wings The aircraft was raised off of the floor to make it easier to weld the lift strut attach fittings into place. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597010411631-L33M21X4KULP9XX9880B/w10.jpg Blog - Wings The lift strut ends have to be machined from round stock aluminum. They will be used to attach the outboard ends of both the forward and aft lift struts to the wing leading and trailing spars respectively. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597010411421-CTWTP7TL0CP921QY28BT/w11.jpg Blog - Wings Round stock inserted into lathe for manual milling. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597010410213-X3QXSPFT15C126LKQO1K/w12.jpg Blog - Wings Finished lift strut ends tapped to 3/8"-24 and drilled for AN4 through bolt. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597010409469-IYZVXT5CFFA4LGCOD7OJ/w13.jpg Blog - Wings Lift strut ends are tested for proper fit with fork rod ends and eye bolts prior to installation. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597010407790-XVW3IJ6GH7SUCDQ99H25/w14.jpg Blog - Wings The ends of the lift struts are drilled to accept the through bolts that will hold the ends in place. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597010407262-H1263GZKTWXFQQVS9N4X/w15.jpg Blog - Wings The hardware that secures the ends of the lift struts to the aircraft is installed. The large clamp temporarily supports the load of the wing during the install process. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597010406247-YHZGB0WF6INOGN3XXNVF/w16.jpg Blog - Wings The wing strut joiners were cut on the waterjet. They function to tie the lift struts together at the base of the fuselage frame. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597010404132-FO40VUO4CORDG6GOHCSI/w17.jpg Blog - Wings Bottom view illustrating the strut joiner. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597010402758-R74E5PHB05EOGLXCZ8GM/w18.jpg Blog - Wings The remaining AN fasteners are installed and tightened. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597010402390-JRQ2JNYW1IOQ00LQ7Y7H/w19.jpg Blog - Wings Same thing for the right wing. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597010400177-DR55AYGQAOAR9VNCKTNZ/w20.jpg Blog - Wings One side completed. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597010399962-OBBM2EFEAQSN23XLJ09U/w21.jpg Blog - Wings The bolt that secures the lift strut end to the trailing edge eye bolt is installed. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597010397764-X6I6DVA1P2YEBR7RA70H/w22.jpg Blog - Wings The wing fold fitting mates the inboard leading edge to the fuselage frame. We will most likely not use the wing fold feature as we will have to completely remove the wings in order to move the aircraft out of the building. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597010397753-GU13TNLLAJW31IC8S02S/w23.jpg Blog - Wings The aileron push-pull tube is shown here connected to the aileron control horn. Next step will be to adjust the linkages to achieve the correct aileron deflection. The rear spar also needs to be drilled to accept a bolt that will secure it to the tail boom. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597010395911-XHVZ8UEN10I52UCQFCAB/w24.jpg Blog - Wings Time to dial-in the dihedral for the wings. First we ensure that the center of the fuselage frame is level. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597010395670-ICL8COJRDV8XKYH4QRVO/w25.jpg Blog - Wings Using an inclinometer app on a smart phone we are able to measure the dihedral angle. Right wing indicates 3 degrees. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597010393758-1R2EMWRAUVEOGDX4V9G8/w26.jpg Blog - Wings Same on left wing. Perfect! https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597010393907-9FDCITJHBRREFIFAR1OI/w27.jpg Blog - Wings E-Hawk stretching its wings. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597010391541-RVCSEMR4DG24CCC2QNW0/w29.jpg Blog - Wings https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597010391594-63S65GSJ5AYXYW6IU175/w28.jpg Blog - Wings https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597010421748-LERB7ZPV6O6W7R5RSXE5/w.jpg Blog - Wings https://ehawk.iolani.org/blog/jury-struts monthly 0.5 2022-04-29 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598507637602-5S97Z74B17YX66UHNITM/jury.jpg Blog - Jury Struts https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597020112216-MGMKZ6HFJO2G3PJH7NKC/s23.jpeg Blog - Jury Struts The first step of the process involves recreating the parts in our CAD system. We basically redraw the part based on the dimensions provided by the pdf file found in the EMG-6 database. From there we can export the dxf files to our water jet cutter. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597020113052-HESYLX4TGONNLMTR0XIG/s22.jpg Blog - Jury Struts Our internal drawing of one of the 6 unique jury strut connectors. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597020118530-V6DE32SLJXCD6CN53P8M/s21.jpg Blog - Jury Struts Freshly cut jury strut connectors. The smaller parts require tabs so that they don't fall into the abyss that is the water jet tank. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597020119302-FNLEPH7B2M8OP7KGDTLQ/s20.jpg Blog - Jury Struts Jury strut connectors cleaned, deburred, and ready for installation. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597020125553-87RZS5L8L756HL0N1OUU/s19.jpg Blog - Jury Struts We decided to print a full scale drawing of the jury strut assembly. We use it as a template to derive the length and angles for the 4 segments of streamline aluminum extrusions. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597020129614-8G0NCBX3ZK5COFWVAJ51/s17.jpg Blog - Jury Struts The 4000 rmp chop saw effortlessly glides through the aluminum extrusion. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597020131998-QOGFIAES74JENP1RDQY5/s16.jpg Blog - Jury Struts For the more drastic angles we turn to the band saw. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597020135962-C8ROJMVMSYRLNH57Q977/s15.jpg Blog - Jury Struts Some light sanding will remove any sharp edges prior to assembly. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597020133160-3H9I03XVC6GG3H2YCUUY/s14.jpg Blog - Jury Struts Strut segments are all cut and the connectors are aligned with the scale drawing prior to drilling. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597020138966-TDTJ31FKHOZD7Y2I1NFO/s13.jpg Blog - Jury Struts Drilling the 3/16" holes to accept the AN3 bolts that will connect the eye bolt. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597020580967-7YJERT8TF3QTQJ401NHY/s26.jpeg Blog - Jury Struts More drilling. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597020144978-SM4PREI74JWJ58G4TZ8S/s11.jpg Blog - Jury Struts The assembly is held and clamped in place while the connector rivet holes are drilled. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597020146935-RGA0NJVUKV4UCRAOXOQT/s10.jpg Blog - Jury Struts Cleco's are used to temporarily hold the parts together. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597020578753-RQOUWWJC90Q3UPZWGD4Y/s25.jpeg Blog - Jury Struts Cordless riveting tool makes quick work in sinking CCP4-3 stainless steel rivets. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597020153126-J5AL6N2JJ5EH6H1WVW5A/s8.jpg Blog - Jury Struts More riveting. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597020151582-BNFIA74XTL6MLYNZWYEC/s7.jpg Blog - Jury Struts Drilling main spar for eye bolt attach point. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597020157394-49YYLQ2X6627DE57ZWQJ/s6.jpg Blog - Jury Struts Attaching the jury strut assembly to the main spar and the trailing spar. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597020157750-HG567JUHWRFIIYJF9AQ1/s5.jpg Blog - Jury Struts Close up of the jury strut attached to the trailing spar. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597020163953-V2TIHYQGVA9LAFYCCOZ3/s4.jpg Blog - Jury Struts Once the jury strut is attached to the wing we position where it will interface with the main struts and then mark and drill for the eye bolt. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597020162751-WUV6TO8NSP6RF4O7FLGE/s3.jpg Blog - Jury Struts Cold bending the lower eye bolt. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597020165781-ATLPDQUL0VAG67FCT8KI/s2.jpg Blog - Jury Struts Here's where the main wing strut interfaces with the jury strut assembly. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597020170845-N1OFFDO8ZT4WNOLHT4ES/s1.jpg Blog - Jury Struts Left wing jury strut complete. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597020171556-WZPJ5PI4JJ32HURI1WAL/s.jpg Blog - Jury Struts A job well done. Can't wait to do the right side. https://ehawk.iolani.org/blog/0lrqtwrjrqw6f2fbz22bejfk7rrft2 monthly 0.5 2022-04-04 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597016736450-UV4EG5ENHHVR9ZCNC6QG/Frame4.jpeg Blog - Fuselage Frame to Tail Boom Assembly https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597016736982-L9D0IYHDGVVNYNHHKMIT/Frame3.jpeg Blog - Fuselage Frame to Tail Boom Assembly https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597016749528-U150LUQ42YUJTMTYT2QK/Frame2.jpeg Blog - Fuselage Frame to Tail Boom Assembly https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597016750671-QK4200CX8QCJF8FMS5Z7/Frame1.jpeg Blog - Fuselage Frame to Tail Boom Assembly https://ehawk.iolani.org/blog/f3yfoypybzypcj5yjaosybsrx0axqa monthly 0.5 2022-04-04 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597017064814-AG9I29RTGV9MDHJHI8KW/Aileron12.jpg Blog - Ailerons We started the build process by deburring all of the aileron ribs. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597017052891-Z3RMM4ASFY2XRQ5T3J30/Aileron11.jpeg Blog - Ailerons Some of the rib halves were missing from our order so instead of waiting for the replacements to ship, we decided to cut our own on the water jet. They were cut from .025" 2024 aluminum sheet. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597017076857-4IBH2ZGGJTEZ5ZKQXVBR/Aileron10.jpeg Blog - Ailerons The next step involved a 90 degree bend in the ribs. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597017085188-LMXM4UWCZ9OMJ3NWGQYD/Aileron9.jpeg Blog - Ailerons Prior to executing any of the riveting we clecoed all of the rib halves together and laid them out as they would attach to the leading and trailing edges of the aileron. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597017109332-YWCDEX5YAH711XABGBYG/Aileron8.jpg Blog - Ailerons After cutting the leading edge of the aileron to length it's time to deburr the edges. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597017109784-21Z5L7W8NG2QFURUUHEB/Aileron7.jpeg Blog - Ailerons The ends of the leading edge are now drilled for the eye bolts that will be used to hinge the aileron to the trailing edge of the wing. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597017115065-SVRE1OIKL1K1NMDMX09U/Aileron6.jpeg Blog - Ailerons The hole locations for the ribs are marked on the leading edge. The ribs are then aligned to the mark, drilled, and clecoed into place. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597017115505-UFKNOECL5HVA9SPFUQAE/Aileron5.jpeg Blog - Ailerons All hands on deck for more drilling and clecoing. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597017120670-URI5QTYYF8G55IJ9BDKR/Aileron4.jpeg Blog - Ailerons Up until now we have used a pneumatic rivet gun to do all the riveting. Our Robotics team recently acquired this cordless, electric riveter which offers a bit more portability (no compressor or hoses) than the pneumatic machines. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597017121124-U4S97E0YNE1WZF08GG4J/Aileron3.jpeg Blog - Ailerons The ribs have been riveted to the leading edge and the trailing edge has been clecoed in place. The last 4 ribs on the outboard side of the aileron are angled up to provide about 1-1/2" of washout. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597017134002-791WI0YUXRNOE6C666Z8/Aileron2.jpeg Blog - Ailerons Left and right ailerons mostly complete. The control horns still need to be riveted on. We will wait to complete this step until we've assembled the wings. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597017138870-HNJUS769MSX098OGPEMA/Aileron1.jpeg Blog - Ailerons We will most likely use Oratex to cover the ailerons. https://ehawk.iolani.org/blog/joav180er0pfrnd64g1wupavxitdko monthly 0.5 2022-04-04 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597017558754-3UZ89889NX78P4LPUBFB/Mount10.jpg Blog - Motor Mount The process begins with 3D printing a model of the motor we will be using. We also created a mock propeller that will help us determine the largest size prop while maintaining ground clearance and clearance to the underside of the tailboom. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597017561502-4HIXGKBMHWHOG3VX6T05/Mount9.jpg Blog - Motor Mount We can use another temporary 3D printed part to prototype the motor mount location with an offset from the existing horizontal tube on the fuselage frame. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597017561511-UOCHRM3S3UKGAST3R6N7/Mount8.jpg Blog - Motor Mount This is a CAD rendering that shows a central tube surrounded by 4 perimeter tubes that will be used to hold the mounting plate in place. We opted for a design where the center tube mounts directly to the existing cross member on the fuselage frame. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597017564028-TLX2WW85SWKLIXVH1ISX/Mount7.jpg Blog - Motor Mount Here's a view from the rear of the frame showing how we plan to attach the motor mount. The central tube is 1" in diameter and the outer supporting tubes are 1/2" https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597017564163-RA25N4F3CVRGNXQ35F7S/Mount6.jpg Blog - Motor Mount This is a drawing of the bottom tube flattened. This will be printed in 1:1 scale, cut out, and wrapped around the tube for notching. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597017567063-0O4ZQJUCLAIA1BZVAL1T/Mount5.jpeg Blog - Motor Mount The motor mounting tubes have been cut to length and notched per the flattened templates. The red circular part is a 3D printed model that was used in the prototyping process to ensure CAD accuracy. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597017566739-ZDKI3U6PSY6UI1SE1UB9/Mount4.jpeg Blog - Motor Mount We begin by welding the center tube to the motor mount plate so that we can do a fit check with the perimeter tubes. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597017573791-DKVIQVVP96VNEVH340YS/Mount3.jpeg Blog - Motor Mount The support tubes have been welded to the motor mount plate. This assembly is temporarily clamped and taped to the fuselage frame for a fit check prior to final welding. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597017572709-CQU5ABOF9QSH3DAJPVNY/Mount2.jpeg Blog - Motor Mount The aft section of the motor mount is fully welded and the assembly is clamped to the fuselage frame to enable the forward section to be welded. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597017575337-2W0VDE2MRIA5HBVPNMSI/Mount1.jpeg Blog - Motor Mount Prior to welding the forward section of the motor mount we will have to strip away the primer from the fuselage frame around the attach points. https://ehawk.iolani.org/blog/hlkt1e7rplauaiuctq1mlayov6t9gt monthly 0.5 2022-04-29 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597018286212-0HGWFHA9JC6IHTMZZGV5/Motor15.jpeg Blog - The Motor The REX 30 motor has a diameter of 205 mm and a height of 46 mm. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597018286055-NXGD8500SWWC2FXDQT28/Motor14.jpeg Blog - The Motor The motor has 6 phase leads exiting the rear which are combined into 3 phase pairs at the controller. The cable bundle exiting in the top of the photo contains the hall sensor signal wires and temperature sensor signal wires. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597018291741-RWK7NZ8JDYEKH8WI9FJR/Motor13.jpeg Blog - The Motor The motor controller is relatively compact and according to the manufacturer is capable of pushing out 33kW continuously. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597018291925-3EFHRP9H0Y1E5WSQ03X6/Motor12.jpeg Blog - The Motor On the back side of the motor controller is visible the heat sink with cooling fans. The quality Rubycon input capacitors are encouraging. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597018296087-H6GNE89XYOKIXPBWP4KR/Motor11.jpeg Blog - The Motor The motor is finally mounted to the fuselage frame. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597018296346-DR5LRPCRY7820JYHBG8M/Motor10.jpeg Blog - The Motor Aft view of the motor. The red disk is a 3D printed mock-up of the motor-to-propeller adapter plate. The prop we will be using requires the standard Rotax 6M8d75 hub bolt pattern. The plate will later be machined from aluminum. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597018300643-0PK8ZO7DBIAKINLM6QC4/Motor9.jpeg Blog - The Motor The motor is fitted with a prototype prop for a fit check. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597018301329-V6K5KTTCW6VFGXWAS557/Motor8.jpeg Blog - The Motor Side view of the installation. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597018301418-ZEUXUB7B7F7HLHY2YVN1/Motor7.jpg Blog - The Motor This is the CAD model for a battery power combiner box. This will allow us to connect 4 6s Lipo batteries with XT90 connectors in series. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597018305126-3VUPFX8LW9HJAU3ENLTI/Motor6.jpeg Blog - The Motor The combiner box is printed, XT90 connectors are inserted and wired in series. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597018305528-MIK0MX54HE8N1WFYP9IR/Motor5.jpeg Blog - The Motor The completed combiner box parts ready for assembly. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597018310037-ZM0ENETUFBJCILL7268B/Motor4.jpeg Blog - The Motor Voltage check of the 24s test battery pack. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597018309647-1MVM56ZX1M5ZK44HNUT9/Motor3.jpeg Blog - The Motor The motor controller is temporarily attached to the fuselage frame. A wooden platform is also installed to support the balance of our test setup. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597018315770-XVG5YA9P5MT4KEK31BYK/Motor2.jpeg Blog - The Motor A 60A circuit breaker is wired in. It will allow us to quickly disconnect the traction pack if anything decides to go wrong. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597018315645-KF2A6DD9442H3CQ5EK5A/Motor1.jpeg Blog - The Motor The control panel from left to right: circuit breaker, precharge switch, auxiliary power (12V control electronics), and controller enable switch. The potentiometer knob is below the aux power switch. The Arduino will be used to read performance data from the controller and later display as flight instrumentation. https://ehawk.iolani.org/blog/opyf1ulrudjwl8qt82gqvdrzryuvqk monthly 0.5 2022-04-29 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597018989798-9PX2ZOZIQD3VLZHTQ7C7/Brakes9.jpeg Blog - Brakes Carefully adding Automatic Transmission Fluid (ATF) to the master cylinder reservoir. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597018987332-TRZY0VAN46QPNMGFE2MZ/Brakes8.jpg Blog - Brakes The CAD models for some mounting parts we designed. The splitter will be sandwiched between the green and blue parts. The remaining parts are standoffs that will hold the brake line in place for routing. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597018990219-062MRNA78ZTF40W3SK12/Brakes7.jpeg Blog - Brakes The splitter is mounted to the frame using the custom 3D printed mount and the brake lines are routed left and right using the standoffs. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597019000298-GZLGYKC8TMKL4MRPFSPS/Brakes6.jpeg Blog - Brakes More sauce (ATF). https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597019000840-5M8RN4TBT4K54YHEA6WI/Brakes5.jpeg Blog - Brakes Bleeding the brakes. The deep red color of the ATF and clear brake lines makes any air in the lines readily visible. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597019006458-TA733F55ZL4Y4U11J2RC/Brakes4.jpeg Blog - Brakes Brake line routing is complete. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597019007313-NANU1MIBNVESKJK3FN25/Brakes3.jpeg Blog - Brakes Brake line routing along the landing gear leg. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597019016919-Y4VHPVSBELSD3LG9BSHR/Brakes2.jpeg Blog - Brakes From the master cylinder the brake line enters the control stick at the top end and exits near the bottom. Rubber grommets are installed at the entry and exit points and will prevent chaffing. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597019017659-QZOFEE5V7TC98HKUDPA0/Brakes1.jpeg Blog - Brakes Brake lever mounted to the stick. https://ehawk.iolani.org/blog/0c35d92zcn2pqbj1weurelghdvx1l9 monthly 0.5 2022-04-29 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598507584401-J6J6ENXK2V9D4DBNXEGP/seat.jpg Blog - Seat Modifications https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597020914492-G9WM53EBPAKV0U5Y11VS/s5.jpg Blog - Seat Modifications https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597020920563-DUEGQRGNN4RLPTGL6PZ5/s.jpg Blog - Seat Modifications https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597020919486-XRZ4DG1937VBZE9E65D1/s1.jpg Blog - Seat Modifications https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597020917102-WF15M1THAEG36QLCSF3X/s2.jpg Blog - Seat Modifications https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597020915104-M5DQ7MK7KOW6VBBXK9D9/s4.jpg Blog - Seat Modifications https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597020917545-AW3JYFQSSWUJI8RMP0HK/s3.jpg Blog - Seat Modifications https://ehawk.iolani.org/blog/xdlm9n24b8w3raizlpv2ye30e01m2i monthly 0.5 2022-04-29 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598400621539-GTPE6C6I3CL27Q6DV8IJ/gr.jpg Blog - Wing Tips The bending jig is made from two 9-inch radius disks. Each disk is cut from 3/4" plywood and then the two halves are glued together. The dowels are used to align the disks prior to gluing. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597878121965-U26SCBOA9I67MLXYF71C/wqrgf.jpg Blog - Wing Tips Here's the drawing of the part we need to fabricate. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597022602286-SFYG9TPEG01I1UEPC8OA/qwrefds.jpg Blog - Wing Tips Setting up the CNC router to cut the parts for the bending jig. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597022601491-2P29FKTMH28BUW25UE7G/rewfdsaz.jpg Blog - Wing Tips First half of the bending die is almost done. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597022599680-52EFZLEMZM4WMV0WZAQK/rqdsa.jpg Blog - Wing Tips The two halves are aligned with the dowels, glued, and clamped. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597022599377-HEZ99FFSR9TFEB6WMNIL/erwdsac.jpg Blog - Wing Tips The bending jig is fastened to one of our heavy work tables. We also fasented the jig we created for the keel t help clamp the tube in place. The 1" tube was filled with sand (actually the abrassive we use with our waterjet) at which time bending commenced. A fair amount of force was required to make this manual bend. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597022597605-1TV7ZFIBOFOWY34A7ZE8/rewds.jpg Blog - Wing Tips A fair bit of force was required to make the first bend of approximately 140 degrees. We had to make sure to apply the bending force as close to the die so as to not introduce any bending in what should be a straight section. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597022597109-SO278TCLXQ38PBW5XK4U/wrefc.jpg Blog - Wing Tips The first bend is complete. Here we are re-positioning the wing tip so that we can proceed with the second bend of about 36°. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597022594900-G72YZHXCT4RLU2V1H7C7/werfdsczx.jpg Blog - Wing Tips We printed a full-scale drawing to make sure that our part was accurate. Multiple bends were made to get it just right. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597022593208-3JSDLYBDXZCCUZXW7W6U/rewfdscz.jpg Blog - Wing Tips The wing tip is held in place with two bolts and a plastic socket that mates it to the larger diameter leading and trailing edges. The leading edge installation is similar to that of the trailing edge. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597022594599-557PRZ5JXP3QURS55WTL/fdscxz.jpg Blog - Wing Tips Locating the the leading edge and trailing edge tip sockets prior to installation. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597022592273-XAMWF1U05O08DH7HE3RW/rewfdscx.jpg Blog - Wing Tips Time to install the left wing tip. A fit check was performed first, then followed by drilling the bolt holes. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597022592426-SE86M4IFAMX4G58KRR6M/fds.jpg Blog - Wing Tips https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597022603714-2YYXBLDRVI615ZDHQJ64/wwed.jpg Blog - Wing Tips The completed wing tip installed. https://ehawk.iolani.org/blog/f16ub20jikma5ivebiis8997d232be monthly 0.5 2022-04-29 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598400492821-KD4FY0I8C9LNCZM41DRR/skinny.jpg Blog - Wings - Ribs and Covering The first step involves sliding the sails over the wing structure. The ribs will be inserted later. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597023492843-1H3X6YG3ZDC0QHRVJ8B5/ed.jpg Blog - Wings - Ribs and Covering Having 3 people work on the task made it manageable. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597023493465-XV0XNXXJUGQXM4UYRMPE/vb.jpg Blog - Wings - Ribs and Covering Inspecting the fit at the wing tip. There are a few zippered access slots in the wing covers. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597023493558-7Y9KHDCAXK5HBH7TM1OQ/cvb.jpg Blog - Wings - Ribs and Covering This is the drawing for the rib bending template. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597023495448-R7SL31WK9IQRDEFPQDLF/xcvb.jpg Blog - Wings - Ribs and Covering We used our CNC router to cut out the rib bending template from 3/4" plywood. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597023495446-R3VM4FNPIXXSBWK5EEWH/fghjd.jpg Blog - Wings - Ribs and Covering We used the chop saw to cut the rib sections from 1/2" aluminum tubing. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597023496977-GED92VUZ0UBG0WHXY8GG/etyu.jpg Blog - Wings - Ribs and Covering Using a couple of toggle clamps and a cutom 3D printed tube holder, we were able to secure the tubing into the jig prior to bending. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597023497547-0SGB1LLW0GMDWL1WXKJG/tryn.jpg Blog - Wings - Ribs and Covering Using a couple of toggle clamps and a cutom 3D printed tube holder, we were able to secure the tubing into the jig prior to bending. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597023499339-GOMQEF0RN9V1HUP8NYO2/kjb.jpg Blog - Wings - Ribs and Covering Teamwork employed to achieve a precise bend. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597023499546-D0JI7T85QBMP4QIJLVOE/tre.jpg Blog - Wings - Ribs and Covering More bending. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597023501216-FS00ENP8LOZ9GUT84FTX/jhd.jpg Blog - Wings - Ribs and Covering https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597023501634-U73UBU749YMFK4F2W4Z1/mnbvc.jpg Blog - Wings - Ribs and Covering Using full-scale plots of the rib profile, we were able to check for part accuracy and consistency. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597023504767-2KPUJZML9L9UZSXHBX61/ytr.jpg Blog - Wings - Ribs and Covering This is Jonah playing with fire. Initially we thought that we had to heat the end of the rib to insert the plastic "duckbill" tips. Later we discovered that the heating was not necessary to insert the plastic parts. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597023504215-G15N2YJ80JPT9TUN583K/jhgfd.jpg Blog - Wings - Ribs and Covering Inserting the front rib tip or "duckbill" (Q20250). https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597023506150-B8185R9WODLBCI1IJ68B/erg.jpg Blog - Wings - Ribs and Covering Straps on the inboard end of the sail allows us to pull it tight towards the fuselage frame. The yellow straps are temporary and will be replaced with the straps from the left wing sail. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597023507300-3PXEZ5FYOZDGRL8K2ESU/sdf.jpg Blog - Wings - Ribs and Covering We are using a soldering iron to cut through the material that is coving the access zipper. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597023509029-FMTRLZNJI5GVP8KVCWQB/gfn.jpg Blog - Wings - Ribs and Covering Taking some measurments to acquire the correct rib length. The wing is tapered so the ribs get shorter from inboard to wing tip. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597023510663-W1CBPQE47WMKTEFLUWFB/fhn.jpg Blog - Wings - Ribs and Covering The ribs are inserted into sleeves that are sewn into the interior of the wing sails. Threading the ribs through the sleeves takes concentration. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597023511501-J3878WIUT0TIAOZG6SU3/hk%2C.jpg Blog - Wings - Ribs and Covering Once the rib is fully inserted, a 3D printed trailing edge rib end is installed. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597023511981-EOEHPOUDW8AN5H809ST4/fghj.jpg Blog - Wings - Ribs and Covering Using the soldering iron to melt holes around the fasteners. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597023513310-GSBH1I0K6SQXRW0V8SHE/drtj.jpg Blog - Wings - Ribs and Covering Underside of the completed right wing covering. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597023491089-UZTKFV4U3GHYRYDA7W19/qw.jpg Blog - Wings - Ribs and Covering The almost finished product looks something like this. We still have to install the lower ribs and increase the inward tension slightly. The shape is still a bit off at the tips and will need some attention. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597023514097-ZBZK1L2KH9CXC07PB7S1/xgfn.jpg Blog - Wings - Ribs and Covering Removing the temporary yellow straps now that the right wing sail has been installed with ribs. The two wing sails then get fastened together at the center and tension is applied. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597023515728-6BQ8SSKTE9Z4P3FN4912/art.jpg Blog - Wings - Ribs and Covering Both wings complete. https://ehawk.iolani.org/blog/7c1uugvk7g47c727ngv989xe6qn233 monthly 0.5 2022-04-29 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598400246366-KMZNNTSSGWN85ODYBXMN/b.jpg Blog - The Battery - Part 1 Workers demonstrate contentment early in the battery pack fabrication process. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598150935640-ANSPH6NRA20HLNKAFHSC/wfg.jpg Blog - The Battery - Part 1 Using an electronic load, we perform discharge tests on our Sony VT6 cells. The cell is rated at 3000mAh with a continuous max discharge of 30A (temperature limited). We will be limiting the discharge to 10A per cell which will yield a max discharge for the pack of 200A. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598150933380-LCLMEG4QH08RWNCGVYRE/gj.jpg Blog - The Battery - Part 1 Here we are seeing about 2750mAh down to 2.8V during a 10A discharge. We don't plan to discharge the cells beyond 3.0V when installed in the aircraft. The 3000mAh rating is for a 200mA discharge down to 2.0V. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598150933587-W91L5XLCAAKCJGZ3MQTI/g.png Blog - The Battery - Part 1 CAD rendering of the 1S20P module. Cells are held in place with standard 18650 battery holders and custom 3D printed ends. Parallel connection are made via spot-welded nickel strips and copper bus bars. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598150932655-9OGH8H6LSCVR1SZWEQ4F/d.png Blog - The Battery - Part 1 CAD rendering shows the overall layout of the pack. The assembly includes cooling fans, main connector, main disconect, contactor, fuse, and DC/DC converter. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598150932645-VNU1W36MEICO57TRO0CH/f.png Blog - The Battery - Part 1 Another view from the top. The enclosure will be welded aluminum. Cover design is TBD. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598150930849-35EE4C2F5MBB2Z1LY4BE/s.jpg Blog - The Battery - Part 1 The cells arrived bare (no insulating washers or heat shrink wrap). After we measured the voltage of all cells to make sure we had no duds, we began to install the insulators and heat shrink. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598150930738-QQV5FMYI768JAAW0R1F3/y.jpg Blog - The Battery - Part 1 Assembly line in place to prepare all 560 (acutually 600 including those used for testing) cells. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598150929085-PI38RXYL3103L6IYQ3K6/r.jpg Blog - The Battery - Part 1 After the cells are wrapped, assembly of the modules begins. Cell holders are configured to arrange the cells in a 2 x 10 array. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598150927429-DMQQQ583FL19MFS98BPR/e.jpg Blog - The Battery - Part 1 Battery modules begin to stack up. We need to produce 28 of them for our 100V nominal pack. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598150926504-HGAL3OZXXLBATKETPZ1J/w.jpg Blog - The Battery - Part 1 Bus bars being cut from 1/8" copper sheet. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598150925390-OBRBSJMQ8KRU6TXF6JN9/k.jpg Blog - The Battery - Part 1 Brass hex nuts are soldered onto the terminal end of the bus bar. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598150923410-FU6C42SM6MO8PQ12Q0CJ/p.jpg Blog - The Battery - Part 1 Bus bars pressed into the custom 3D printed module tops. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598150922691-FCOI84FLQ3L737XF7WY5/x.jpg Blog - The Battery - Part 1 The nickel strip (0.2mm) is soldered to the the copper bus bar using heat gun and solder paste. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598150920861-0TJPN2LP67ORUKMQWI23/c.jpg Blog - The Battery - Part 1 Completed bus bars receiving a cleaning bath in isopropyl alcohol to remove any flux residue. All bonding surfaces must be clean prior to spot welding. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598150920711-4C4ZQ7KB220R5R73VM3J/v.jpg Blog - The Battery - Part 1 Bus bars ready to be spot welded to the cells. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598150918483-6XF3QMHO4OUYNIIH3YCO/n.jpg Blog - The Battery - Part 1 Here is our custom Arduino-driven spot welder. The pulse duration can be adjusted to optimize the weld. We used 2 deep cycle lead acid batteries as the power source. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598150918681-0MMJZP51S4ZFNV3MC6M3/m.jpg Blog - The Battery - Part 1 The negative side of this module has been spot welded. We perform 3 welds per battery terminal, both on the positive and negative ends. That's 3,360 welds for the entire pack. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598150916179-127NU5R3F640IIES5IU8/q.jpg Blog - The Battery - Part 1 A completed battery module without the insulating side covers installed. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598150916078-OMIJB2QJJGPSD16DE2VN/er.jpg Blog - The Battery - Part 1 Side covers installed. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598150914391-AL4USS0SH3O57JOJIF8K/dtyk.jpg Blog - The Battery - Part 1 The all-up module weight of 1186g translates into a pack energy density of roughly 168Wh/kg (based on useable energy at 10A discharge). This will decrease some when we add in the weight of the enclosure. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598150914286-9RWWN4YG8PTFM4BK8CSA/xfgn.jpg Blog - The Battery - Part 1 Prior to assembling all 28 of the modules, we did a high current discharge on a test module to make sure it held up. The test setup consists of the battery module connected to a custom made power resistor through a fuse and main disconnect switch. The resistor was submersed in ice water so as to keep its resistance constant for the duration of the test. The resistor was sized to sink approximately 200A which is our anticipated max current draw. At 25C ambient temperature, a 6 minute, 200A discharge yielded a battery temp increase of 21°C and a bus bar temp increase of 11°C. The greatest increase in temperature was in the #4 wire as it increased by 31°C. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598150912027-82P17TCUFCI7EN75MA2T/fghj.jpg Blog - The Battery - Part 1 At 190A our 28S pack would be providing roughly 19KW of power. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598150911316-7ATRRNPP2RCVS1NH1MBW/srt.jpg Blog - The Battery - Part 1 Using the waterjet to cut battery module connectors from copper plate. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598150910460-RT75IEW74Y8UWJTQUUCI/vc.jpg Blog - The Battery - Part 1 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598150908575-1QE3F7856O9X45JP3XBH/adf.jpg Blog - The Battery - Part 1 The modules are configured in series using copper terminal connectors secured with 1/4-20 fasteners and wedge lock washers (Nord-Locks). It's not obvious from the picture but each of the 7 modules in a row is mechanically interlocked with the adjacent module via the cell holders. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598150908170-Z748ODX3QJK0XZ5EBG1D/hfgh.jpg Blog - The Battery - Part 1 Cardboard prototype of the battery enclosure is evaluated prior to aluminum fabrication. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598150905588-S3BLI2XX6KK2PUBBUE6X/hjm.jpg Blog - The Battery - Part 1 Modules installed in prototype enclosure with balance of electrical components. Each row of 7 modules will be separated with electrical grade fiberglass (GP03) sheet. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598150905402-57AZ75IX80OJ3N9S2HB4/wrt.jpg Blog - The Battery - Part 1 Aft (air exhaust) side of pack. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598150903158-R20T94IURN87QPQVTXYL/fhj.jpg Blog - The Battery - Part 1 Cooling air intake side of enclosure. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598150903259-VENCLRKRTIN1N0JAVO38/cvb.jpg Blog - The Battery - Part 1 Battery pack fit check. https://ehawk.iolani.org/blog/elevator-bellcrank-fabrication monthly 0.5 2022-03-30 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598343201026-O7KOHRHDH4EKYI5XFJKS/fork_bolt-1.jpg Blog - Elevator Bellcrank Fabrication Since we do not have all of the linkage hardware at this time we quickly modeled the missing fork bolt and 3D-printed a couple so that we could connect the control horn to the elevator and test the elevator range of motion. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598343213761-87AJV12KRLTUJE4U4B3Q/IMG_3460-Large.jpg Blog - Elevator Bellcrank Fabrication The 4130 alloy 1/8" plate is loaded and clamped to the bed of the machine. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598343227639-TX9VER1NCH89GBRY2Z1K/IMG_3462-Large.jpg Blog - Elevator Bellcrank Fabrication The dxf files for the control horns are loaded into the water-jet software where the layout and machine setup take place. The parts on the screen will take 10 minutes to cut and use about 7 pounds of abrasive. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598343238752-KI40JX4YFE9OMIE2WQ66/IMG_3477-Large.jpg Blog - Elevator Bellcrank Fabrication After the completed cut you can see a risidual layer of the abrasive on the plate. The spent abrasive collects at the bottom of the tank. After about a year of use we drain the tank and remove the used abrasive and waste material from the parts. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598343243302-2JB5OHQDVS33VOKZ2JTI/IMG_3484-Large.jpg Blog - Elevator Bellcrank Fabrication Note also the precision of the cut. After minimal deburring the parts are ready for assembly. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598343249726-Q9X70F51DN1H1W7KW2JI/IMG_3488-Large.jpg Blog - Elevator Bellcrank Fabrication Here we do a quick tolerance test on the 3/4" holes. The fit is so perfect that the control horns hold their position on the tube. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598343272654-BA64KUWP57IVRCJ9ZZHU/IMG_3487-Large.jpg Blog - Elevator Bellcrank Fabrication Close-up of the cut parts. Note that we added tabs so that the relatively small parts don't fall between the slats and sink to the bottom of the 'swamp'. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598343284944-Y50XE00F87I0BSSLRKS1/IMG_3718-1-Large.jpg Blog - Elevator Bellcrank Fabrication Next, using the lathe, we machine some aluminum tubing that will be used to firmly hold all the parts together for welding. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598343289320-5K9OINM8N51DJ2423LC3/IMG_3728-Large.jpg Blog - Elevator Bellcrank Fabrication The tooling is in place and checked against the drawing for correct alignment. Threaded rod is used to fasten the assembly in place. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598343296806-BOHI739SI6NB3NU7SVYD/IMG_3732-Large.jpg Blog - Elevator Bellcrank Fabrication The center control horn has been tack welded here. Now we do a final fit check of the assembly installed on the tail boom prior to completing all of the welding. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598343303012-04J9LW8WP5KE0ZL4271L/IMG_3734-Large.jpg Blog - Elevator Bellcrank Fabrication After the assembly has been welded, we will remove the fasteners and unfortunately have to destroy the tooling because it cannot be removed without cutting it free. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598343308410-BM8B90UXR3NSPZ9E7BK7/IMG_3783-1-Large.jpg Blog - Elevator Bellcrank Fabrication All welding complete. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598343314989-0AKXHUUX6BDBG73IG1TQ/IMG_20180412_075620613-Large.jpg Blog - Elevator Bellcrank Fabrication Completed assembly installed. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598343320570-Z8TFV1YEN5RCU7TYRWI7/IMG_20180412_120838145-Large.jpg Blog - Elevator Bellcrank Fabrication A view from the other side. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598343326310-52PX2QN9IBPWXMYYXO7Y/IMG_20180412_120901154-Large.jpg Blog - Elevator Bellcrank Fabrication The 3D-printed fork bolts are threaded into the elevator push-pull tube and attached to the corresponding eye bolt for a quick test. The 3D-printed parts have just enough strength to do the test. They will eventually be replaced with flight certified hardware. https://ehawk.iolani.org/blog/building-egress-test-2 monthly 0.5 2022-04-04 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598344201997-YENLJYQ6VCRTCOFT75YE/20181013_112533-Large.jpg Blog - Building Egress Test #2 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598344206236-ORNWJ129BH2AYY0KXIN3/IMG_4936.jpeg Blog - Building Egress Test #2 Preparing the assembly for transport. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598344209847-PX4HV8ORAQVJV08FCOI0/IMG_4949.jpeg Blog - Building Egress Test #2 It's not looking so good as we enter the first turn in the stairwell. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598344216042-ITKHF1IN4ZIY3XMK6TA0/IMG_4971-Large.jpeg Blog - Building Egress Test #2 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598344221373-80ISIJCH3NNC8Z5WZRJ8/IMG_4978.jpeg Blog - Building Egress Test #2 Bolting the fuselage frame to the fuselage boom. https://ehawk.iolani.org/blog/hp4og9g2le0fb28nug75e9oo9wu9t5 monthly 0.5 2022-04-04 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598344739662-FYKWUA78N4W72RB3VCGU/done-Large.jpeg Blog - Forward Fuselage Frame https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598344743195-3RCZZT4LYE6VH4I4GN1O/drilling-keel-pocket-Large.jpeg Blog - Forward Fuselage Frame https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598344747708-NGSMCRX582B4KSYH8ZKQ/IMG_4664-Large.jpeg Blog - Forward Fuselage Frame https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598344751344-GLVKH79CJFVVG9DS8VFX/IMG_4673-Large.jpeg Blog - Forward Fuselage Frame https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598344755079-X51UN1CWDT6A820LDW05/keel-drilling.jpeg Blog - Forward Fuselage Frame https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598344758185-R1JQNV536WGLRBU6J8U5/nose_skid_tube-Large.jpeg Blog - Forward Fuselage Frame https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598344761431-AIO9DD7T0J2WJ32JZY2D/rudderBar1-Large.jpeg Blog - Forward Fuselage Frame Instrument panel to rudder pedal connection. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598344765904-0PVPRGQJS9N5HRHPQTUV/rudderBar2-Large.jpg Blog - Forward Fuselage Frame https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598344769918-YEU18BB28P62KDTFQVPE/rudderBar3-Large.jpg Blog - Forward Fuselage Frame Keel pockets located on lower keel tube. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598344851120-50AJWC6FH5N7DMLTFQU8/done-Large.jpeg Blog - Forward Fuselage Frame Completed forward section of the fuselage frame. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598344861662-5VL08V4OFP356T4X0T7C/drilling-keel-pocket-Large.jpeg Blog - Forward Fuselage Frame Now with the lower keel back in place we drill through the keel pocket into the keel tube for correct alignment. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598344868759-BV3C08W05HS0M5487AXI/IMG_4664-Large.jpeg Blog - Forward Fuselage Frame Clamping the instrument panel keel pocket to the upper keel tube for drilling. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598344879647-G1Z3I4V2QR3EIC7UHQM8/IMG_4673-Large.jpeg Blog - Forward Fuselage Frame Appears to be a perfect fit. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598344891223-ONIVK2M3KQ0RER3F2FJN/keel-drilling.jpeg Blog - Forward Fuselage Frame Drilling the forward keel pocket. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598344896459-GF6TL6TSZ5946FJXEIDK/nose_skid_tube-Large.jpeg Blog - Forward Fuselage Frame Nose skid tube tacked into place. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598344907178-8R4D6T4HYJLLCNFMMK8H/rudderBar2-Large.jpg Blog - Forward Fuselage Frame Rudder bar is clamped to keel pocket via standoff for welding. https://ehawk.iolani.org/blog/igikxvb95wci72if8y8ud4k1hg23sk monthly 0.5 2022-04-04 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598345209294-JJQE7UW88OUOPSQXRS3R/20181011_161634-Large.jpg Blog - Fabricating Wing Parts Test firing the machine, first with water only followed by water and abrasive at high pressure. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598345216644-Q2MWXXIUUB6I23KBLKKU/20181011_164003-Large.jpg Blog - Fabricating Wing Parts Although Hawaii does not have many fireplaces, this student has managed to find one. Please contact us for our chimney sweeping rates. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598345222550-XAAZXJ6OL1N62VTUND3H/20181011_1623550-Large.jpg Blog - Fabricating Wing Parts The tab remains and will have to be grinded flush. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598345230843-624W5CZ83SPS6ER84PT9/IMG_4847-Large.jpeg Blog - Fabricating Wing Parts Here is a finished set of 20 Diagonal Attach Plates plus a spare. These will be used to reinforce the attachment of the diagonal struts to the leading and trailing edges of the wing. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598345236117-VV02TK8VZUW1UNQXOQAK/IMG_4856-Large.jpeg Blog - Fabricating Wing Parts Here we are using the provided PDF drawings to recreate the parts in Onshape, our CAD software of choice. From there we can generate the DXF files to be loaded in the OMAX layout program. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598345245895-3WFAWORCBGUHMOO5C4RC/IMG_20181011_161334924-Large.jpg Blog - Fabricating Wing Parts In this step the machine is homed and the z-height set. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598345253674-PLA2HDFNPVIIX14FECCN/IMG_20181011_161519714-Large.jpg Blog - Fabricating Wing Parts Here we have loaded the DXF file into the OMAX program and begin laying out the 20 copies of the part. Tabs are added, the cut quality specified, and the material parameters set prior to generating the machine path. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598345258407-T6FTLSAN8DITP8AYLMLU/IMG_20181012_054601404-Large.jpg Blog - Fabricating Wing Parts The next morning parts are removed from the tumbler and cleaned. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598345265384-1ZGT1HR7LO3ESDTD3OMZ/IMG_20181012_055543262-Large.jpg Blog - Fabricating Wing Parts What's left of the 0.125" 6061 aluminum sheet. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598345269555-YEF1Z450FHH7WK5ZLZ20/IMG_20181012_055723686-Large.jpg Blog - Fabricating Wing Parts The cut parts will be tumbled overnight to smooth out any sharp edges. https://ehawk.iolani.org/blog/ipdkcofdu765o4f0a62afwmktw0u3t monthly 0.5 2022-04-04 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598345633177-E557NSGI101BN72KE33K/bending-die-1.jpeg Blog - Bending the Lower Keel Tube Closeup of the die wall showing the radius to match the 1" OD tubing. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598345778439-S1T39JNIH2LUMI3RPHUL/bending-die-2.jpeg Blog - Bending the Lower Keel Tube Assembled tooling fastened to a work table. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598345784516-BC7Z563MK8IHKS98UJX9/bending-lower-keel.jpeg Blog - Bending the Lower Keel Tube The bend in progress. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598345791580-HID9SEWWP24G559DUM5N/checking-bend-angle.jpeg Blog - Bending the Lower Keel Tube Verifying the angle of the bend. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598345803043-ZVQLE93HF1L9NX0LMPG6/die-fabrication.jpeg Blog - Bending the Lower Keel Tube https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598345803552-GGZGIMYN5WPWOWM81ZRO/E-Hawk-_-lower-keel-assembly-page-001.jpg Blog - Bending the Lower Keel Tube CAD of the bending die to be routed from two layers of 3/4" plywood. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598345811543-4JYXLCYZ42WD686USHST/emptying-sand.jpeg Blog - Bending the Lower Keel Tube Emptying the sand after a successful bend. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598345842850-N7UWR24BI0GCP9AD5OX1/die-fabrication.jpeg Blog - Bending the Lower Keel Tube Cutting the tube bending die halves on the CNC router. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598345859714-D1IEB3AGGE6DHSQ4Z6QD/IMG_4654-Large.jpeg Blog - Bending the Lower Keel Tube Triming the end of the lower keel. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598345874319-Z1OX7UAC7TIDA9R0WYS9/IMG_4664-Large.jpeg Blog - Bending the Lower Keel Tube https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598345880378-1XD5K94QL4OW8KSD0S6R/IMG_4673-Large.jpeg Blog - Bending the Lower Keel Tube Pilot fit check. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598345937431-INTH0QEYHIS13HEL5Z5I/IMG_4664-Large.jpeg Blog - Bending the Lower Keel Tube Installing the keel by clamping in place prior to drilling. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598345947305-IE1NL5H5OLFREAHR2TEN/keel-test-fit.jpeg Blog - Bending the Lower Keel Tube Lower Keel test fit. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598345950275-3QG73YIRW49Q5VVIGQVE/Lower-Keel-DRW-page-001.jpg Blog - Bending the Lower Keel Tube Bend specification drawing. https://ehawk.iolani.org/blog/0tbngeyqozr2g530tu2df87gzok5pr monthly 0.5 2022-03-30 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346448530-Z30HCPFNSRVP2DDVRLL9/IMG_3809-Large.jpeg Blog - Progress Up To Summer Break https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346453329-22TBYMCECU7PHIS8V3D2/IMG_3834-Large.jpeg Blog - Progress Up To Summer Break Once the tubes were properly fitted it was time to hold the sub-assemblies together using clamps and bungee cords. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346508021-0BCGAOPIJAVEIG5MGUGC/IMG_3809-Large.jpeg Blog - Progress Up To Summer Break This is the first time that the 3 main sub-assemblies (wing box and forward and aft bulkheads) are test fitted together. The initial fit was good and only minimal tube grinding modifications were required prior to weld-up. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346514164-JD61SA7M6FWURJBI7MIP/IMG_3840-Large.jpeg Blog - Progress Up To Summer Break The triangular main structure moved into the welding station for tack-up. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346521707-AIPNQEC5IYC5BGG213E9/IMG_3851-Large.jpeg Blog - Progress Up To Summer Break Our volunteer expert welder Terry helps the process along. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346531448-ZLM25PEIYY1AGL8P3LNF/IMG_3876-Large.jpeg Blog - Progress Up To Summer Break The main structure of the fuselage frame is fully welded here so an obligatory fit check with the tail boom was performed. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346541404-O5R9QJCBD47UGGVDCXGJ/IMG_3879-Large.jpeg Blog - Progress Up To Summer Break The wing box mounting holes align perfectly with the tail boom and 1/4" fasteners are temporarily inserted to hold the two parts together. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346552601-UIUGCA7L99KNAWXU7CK6/IMG_3881-Large.jpeg Blog - Progress Up To Summer Break It's looking more and more like an airplane. Once we get the keel on the fuselage frame we will be dealing with the full length of the aircraft. At that point we will make another attempt to move the structure out of the building. If it fits down the stairwell we won't have to find a new location for final assembly. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346565402-M24Q76W9XWDA7XYIAF2R/IMG_3882-Large.jpeg Blog - Progress Up To Summer Break A view from the other side. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346578511-L8XE6DUB1G1QYP0ECEUO/IMG_4054-Large.jpeg Blog - Progress Up To Summer Break The fuselage frame moved to the welding station where the pilot seat will be tack welded into place. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346587924-RSAITY91HMDUBWJ9RIKK/IMG_4059-Large.jpeg Blog - Progress Up To Summer Break The pilot seat sub-assembly is held in place with the plywood tooling fixture. The jig locates the pilot seat precisely and holds it in place during welding. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346600441-EFHWES431JNSA9XHCFTE/IMG_4060-Large.jpeg Blog - Progress Up To Summer Break Clamps are used to secure all of the components. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346613108-O9J9VD05C02J99OAZTJV/IMG_4069-Large.jpeg Blog - Progress Up To Summer Break The left and right passenger seat tubes are tacked in place and the aft bulkhead to forward bulkhead diagonal is held in position with tape just prior to tack-up. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346622653-A3Q97SCL5QPHUEBM62YZ/IMG_4130-Large.jpeg Blog - Progress Up To Summer Break Note the seat tabs are already welded to the pilot seat sub-assembly. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346632514-OFU53BMRPHC0Q6JCMLDL/IMG_4131-Large.jpeg Blog - Progress Up To Summer Break The Passenger Seat Transition Tube is shown here connecting the forward bulkhead to the aft end of the pilot seat. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346643695-5XCOZZZA5J7LN0A1MOPO/IMG_4133-Large.jpeg Blog - Progress Up To Summer Break The pilot seat is now welded to the fuselage frame. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346654322-X107GWKLUHSVAKXD30C0/IMG_4147-Large.jpeg Blog - Progress Up To Summer Break Another view of landing gear box sub-assembly in position. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346666575-OVE4D9LYD0HGUVRUVZ0R/IMG_4148-Large.jpeg Blog - Progress Up To Summer Break The next sub-assembly to be added is the landing gear box. More plywood tooling jigs are used for positioning. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346678575-CTD0PQJMK0GB5YXH95C1/IMG_4150-Large.jpeg Blog - Progress Up To Summer Break In addition to the welding fixtures, we measure distances left and right to make sure that everything is centered with respect to the fuselage frame. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346688805-3N6GNMOEMPB9968RBS3Z/IMG_4154-Large.jpeg Blog - Progress Up To Summer Break Closeup of the gear box tube partially welded in place. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346699762-TAF8KGTBSXLXB39IIATI/IMG_4173-Large.jpeg Blog - Progress Up To Summer Break Here you can see that the Forward Seat to Gear Box tube has been welded in place. The two new parts are the Left and Right Forward Pilot Seat to Gear Box and the Left and Right Brake Mount tube which again are held in place using the tooling fixtures, clamps, and some tape. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346708096-4V5FAWJD0KOVHKQJJPYS/IMG_4175-Large.jpeg Blog - Progress Up To Summer Break Closeup of tube fitment prior to welding. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346723712-LMUOW6WH522IG4KCT82C/IMG_4176-Large.jpeg Blog - Progress Up To Summer Break https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346726887-9ERKA3MUYFES102Z1UMX/IMG_4212-Large.jpeg Blog - Progress Up To Summer Break The Landing Gear Box and Pilot Seat are now permanently installed. The fame now stands on its own. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346758847-V7T5ELU4AL4IDSXY7LMO/IMG_4176-Large.jpeg Blog - Progress Up To Summer Break https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346775422-E951OGHPM5XSLT87XSWQ/IMG_4225-Large.jpeg Blog - Progress Up To Summer Break Next up is the Instrument Panel sub-assembly. More tooling helps to locate the placement of the instrument panel with respect to the rest of the frame. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346784238-0QRJVYUN33S50PN1B7KO/IMG_4320-Large.jpeg Blog - Progress Up To Summer Break The bottom end of the instrument panel is clamped to the front end of the pilot seat. The plywood jig is inserted to ensure proper spacing between the legs of the instrument panel. We then measure left and right to ensure that the instrument panel is centered on the frame. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346792455-QXO3XJJ1YIKD3KTDR7KE/IMG_4323-Large.jpeg Blog - Progress Up To Summer Break The 1" tube acts as a temporary keel that is placed into the keel saddle which will be welded to the top of the instrument panel. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346800418-7U7NI7H47CIMETLXFZ3Z/IMG_4330-Large.jpeg Blog - Progress Up To Summer Break Next up is the Forward Spar Keel Pocket. The 1" aluminum top keel is used to align the pocket prior to welding. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346809322-DJSWWJP6SEYGI6ETIDAC/IMG_4344-Large.jpeg Blog - Progress Up To Summer Break Here's what the fuselage frame looks like to date. The top keel will most likely have to be replaced as the bend radius on the existing part is not quite right. We are currently working on creating tooling that will allow us to bend the upper and lower keel accurately per the drawings. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346820411-SJG7EWUAUCDMEETE1G0W/IMG_4346-Large.jpeg Blog - Progress Up To Summer Break The keel socket with the top keel fitted and drilled. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346830606-X79AE1993LLW9H211JEN/IMG_4348-Large.jpeg Blog - Progress Up To Summer Break Top keel has been fitted to the keel pocket. It will be trimmed to length such that it reaches about mid-span of the keel pocket. Later the lower keel will be connected using a splice tube. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346843610-P3JHD247KGL89ZZTXC3T/IMG_4350-Large.jpeg Blog - Progress Up To Summer Break This is the Aileron Aft Bellcrank prior to welding. It consists of the bellcrank cut from 4130 plate which gets welded to a small length of tube. The interface angle is 15 degrees from perpendicular so we designed and printed a sacrificial jig to accurately hold the two parts in place during tacking. The spot welds had to be fast as the heat would quickly propagate to the PLA plastic. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346855891-29D7ZBGXY8M1U5U2BW9N/IMG_4354-Large.jpeg Blog - Progress Up To Summer Break The 3D-printed tooling lasted just long enough to get the tacks into place. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346868606-8W1C25QK9C80NSQW4W0C/IMG_4362-Large.jpeg Blog - Progress Up To Summer Break Here's an assortment of some of the fabricated flight control parts. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346877558-RXEFSZENWIUN0KT6EWV6/IMG_20180529_143807687-Large.jpg Blog - Progress Up To Summer Break Seat braces are added here. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598346886957-4ZBV5NO4B8OWXXE2G0LS/IMG_20180529_143932357-Large.jpg Blog - Progress Up To Summer Break Instrument panel welded to the pilot seat. https://ehawk.iolani.org/blog/0niul8k5yjj6ucgj5w9abt32ldeikd monthly 0.5 2022-03-30 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598348009105-37S5679L9B52H6UW37WF/contoll-tooling1.jpeg Blog - Machining Seat Tabs and Control Arms The Control Stick U-Joint Mount is comprised of a short section of tube and an arm that needs to be welding together. The tube must be centered about the lower hole on the arm and to accomplish that we once again rely upon 3D-printed tooling to hold the metal parts in place for a tack weld. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598348022499-9M4H2GDJMP7C8X7ZUMJ8/control3.jpeg Blog - Machining Seat Tabs and Control Arms The Control Stick Mount is welded and fit checked with the other half of the assembly. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598348030401-XF774W9R5GEQGKU3HV0A/controll-arm1.jpeg Blog - Machining Seat Tabs and Control Arms Elevator control stick torque tube arm. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598348041052-7P3NDC42FKAZ1RXI5HDS/control-tooling2.jpeg Blog - Machining Seat Tabs and Control Arms Tube centered and ready to weld. The tack welds are quick enough that they don't overheat and melt the plastic tooling. It does not take much heat to melt PLA plastic. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598348050354-GE1R6PLPF8UHXEAOY0E2/crank-robot1.jpeg Blog - Machining Seat Tabs and Control Arms Control Arm Robot. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598348060307-7PNCPO0SF8N5IJUD4P7T/cut1.jpeg Blog - Machining Seat Tabs and Control Arms After drilling we use a 3/4" 4-flute center cutting end mill to cut the radius on the end of the seat tab. This cut will conform perfectly to the 3/4" tube that the tabs will be welded to. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598348066621-8SO5C04YM44EYZO43SS0/cut2.jpeg Blog - Machining Seat Tabs and Control Arms Preparing to execute the manual plunge into the part using the jog wheel. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598348075194-GRN52E08XUFG64EKGFEJ/drill2-1.jpeg Blog - Machining Seat Tabs and Control Arms Using our CNC Mill in manual mode to drill the 1/8" holes into the 30+ seat tabs. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598348083704-A1CG8Y3SAV9VH5NAFU2F/seat-tabs-fit.jpeg Blog - Machining Seat Tabs and Control Arms Seat tabs are complete and a quick fit check is performed. Next step is to weld them onto the pilot seat sub-assembly. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598348101793-ASAR4LPD7CD9E24SWACV/tabs-drilled.jpeg Blog - Machining Seat Tabs and Control Arms The holes have been precisely located along one edge and centered on the other using the edge finder. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598348112643-B0CKLL6D2GPQ7OVNAVZ6/waterjet1.jpeg Blog - Machining Seat Tabs and Control Arms Another batch of parts cut from 0.090" 4130 steel. Tabs are added to prevent the parts from falling into the water tank. Some light cleaning on the wire brush wheel and the parts will be ready for welding. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598348120430-J2ZE50C3LRRZ7EL6R1V8/waterjet2.jpeg Blog - Machining Seat Tabs and Control Arms Layout of the control parts in the OMAX Make software. These parts are cut from 0.125" 4130 steel and the estimated cut time is 27 minutes. https://ehawk.iolani.org/blog/e-hawk-team-hawaii-eaa-fly-in monthly 0.5 2020-08-28 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598348800785-95HDFSQ2ABEZCZ0NPW4L/IMG_1164-Large.jpg Blog - E-Hawk Team @ Hawaii EAA Fly-In https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598348812663-JW8GDMIVOKSNZUOM7QZN/IMG_1171-Large.jpg Blog - E-Hawk Team @ Hawaii EAA Fly-In https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598348821509-7HHQHG0NJ4QQT19XSPT2/IMG_3906-Large.jpeg Blog - E-Hawk Team @ Hawaii EAA Fly-In https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598348833638-SN8B2WJJOF1RD0MSKL4J/IMG_3908-Large.jpeg Blog - E-Hawk Team @ Hawaii EAA Fly-In https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598348843488-RRSEUS7QS84PMQAG5P46/IMG_3917-Large.jpeg Blog - E-Hawk Team @ Hawaii EAA Fly-In https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598348855248-2LWDNO99BUEPDQW3WCV4/IMG_3920-Large.jpeg Blog - E-Hawk Team @ Hawaii EAA Fly-In https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598348867150-ZJ1OAJ5LPHBT3AVVDZB7/IMG_3966-Large.jpeg Blog - E-Hawk Team @ Hawaii EAA Fly-In https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598348883245-UG8IGGC8Q95ZHCCBI9I2/IMG_3992-Large.jpeg Blog - E-Hawk Team @ Hawaii EAA Fly-In https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598348896638-8HK9TGMS7W8ROIUX9H8T/IMG_3994-Large.jpeg Blog - E-Hawk Team @ Hawaii EAA Fly-In https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598348905019-VLN760H79ITEW509I76I/IMG_6847-Large.jpeg Blog - E-Hawk Team @ Hawaii EAA Fly-In https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598348913766-OF6T67RVFH50S2RP0QVI/IMG_6850-Large.jpeg Blog - E-Hawk Team @ Hawaii EAA Fly-In https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598348921064-C818XZU8R3V3DXM9J5EC/IMG_6851-Large.jpeg Blog - E-Hawk Team @ Hawaii EAA Fly-In https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598348929920-N4APBO1W5WZ57ZHBQUXX/IMG_6855-Large+%281%29.jpeg Blog - E-Hawk Team @ Hawaii EAA Fly-In https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598348935068-LHJCG5IALRTJZH0Z6DD5/IMG_6856-Large.jpeg Blog - E-Hawk Team @ Hawaii EAA Fly-In https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598348947601-PEU6XBND5ZL1S5FSG658/IMG_6859-Large.jpeg Blog - E-Hawk Team @ Hawaii EAA Fly-In https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598348953109-P02A89BVT59WAX42ENJ8/IMG_6873-Large.jpeg Blog - E-Hawk Team @ Hawaii EAA Fly-In https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598348957035-E99H66BX0VHJG2R2R12W/IMG_6874-Large.jpeg Blog - E-Hawk Team @ Hawaii EAA Fly-In https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598348967566-M1IJSOQ6HSBQF9D48OH0/IMG_6877-Large.jpeg Blog - E-Hawk Team @ Hawaii EAA Fly-In https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598349010014-S8KTS36KV84MK0XWPVT3/IMG_6873-Large.jpeg Blog - E-Hawk Team @ Hawaii EAA Fly-In https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598349017832-XELI5OHO0MMVCJA0E67D/IMG_6881-Large.jpeg Blog - E-Hawk Team @ Hawaii EAA Fly-In https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598349029385-NZP681G6APJPXTAP1PDN/IMG_6883-Large.jpeg Blog - E-Hawk Team @ Hawaii EAA Fly-In https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598349036878-YO5OGMA6JE2VZ8CX7X2Z/IMG_6885-Large.jpeg Blog - E-Hawk Team @ Hawaii EAA Fly-In https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598349045782-GP4GRX8I56OPWPIU4KD1/IMG_6891-Large.jpeg Blog - E-Hawk Team @ Hawaii EAA Fly-In https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598349056686-AVV28Z75JQRD2M0T5SHL/IMG_6900-Large.jpeg Blog - E-Hawk Team @ Hawaii EAA Fly-In https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598349074646-QPB8VXA13P7TN3UUZ5F6/IMG_6925-Large.jpeg Blog - E-Hawk Team @ Hawaii EAA Fly-In https://ehawk.iolani.org/blog/g970ak3uq3ktmk0ky3por2ff43he9f monthly 0.5 2022-03-30 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598349601268-DVNQHB5AZ9RJGNILHZ2G/IMG_3757-Large.jpg Blog - Horizontal Stabilizer Outboard Rib and Aft Elevator Push-Pull Tubes https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598349627440-BYIJN3TK6LV4HC06PNNO/IMG_3760-Large.jpg Blog - Horizontal Stabilizer Outboard Rib and Aft Elevator Push-Pull Tubes https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598349645241-91Y7TIQL0K63MN0E81EC/IMG_3762-Large.jpg Blog - Horizontal Stabilizer Outboard Rib and Aft Elevator Push-Pull Tubes https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598349663799-6LIR8MDNS7ET8SSIHM2G/IMG_20180327_154010384-Large.jpg Blog - Horizontal Stabilizer Outboard Rib and Aft Elevator Push-Pull Tubes https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598349670455-TCEDEEQIK30ODX47IFPF/IMG_20180327_155011695-Large.jpg Blog - Horizontal Stabilizer Outboard Rib and Aft Elevator Push-Pull Tubes https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598349679907-FTE5POIWTHXZ05A0CS1A/IMG_20180327_155026741-Large.jpg Blog - Horizontal Stabilizer Outboard Rib and Aft Elevator Push-Pull Tubes https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598349690571-CJGQK00SFH4GI3C1IZ7F/IMG_20180327_155715658-Large.jpg Blog - Horizontal Stabilizer Outboard Rib and Aft Elevator Push-Pull Tubes https://ehawk.iolani.org/blog/fsndnul1x90qfq9br7tv4qgtutvmzi monthly 0.5 2022-03-30 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598349956610-Z8F1T6SN2ROHSLXBDAHQ/FuselageFrameCAD.png Blog - Fuselage Frame Progress Here's what we are working toward. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598349970255-X031UWTIFA13E7YARSAY/IMG_3615-Large.jpg Blog - Fuselage Frame Progress Aft bulkhead tubes have been coped and fitted into the tooling. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598349979569-TTVH6Q14BRJ40UIRCLVF/IMG_3616-Large.jpg Blog - Fuselage Frame Progress A tight fit will simplify the welding. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598349987353-Z4N1JN6U8JU6LLYXJ6QG/IMG_3618-Large.jpg Blog - Fuselage Frame Progress The top and bottom tubes of the aft bulkhead are placed in the jig to confirm proper fit yet they will not be welded. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598349996371-T6V5SR5YJYLJ8EAYFOO6/IMG_3626-Large.jpg Blog - Fuselage Frame Progress The aft bulkhead moved to the welding area. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598350007172-7HBMMRS39X7183KJB8WO/IMG_3712-Large.jpg Blog - Fuselage Frame Progress Completed sub-assemblies. Next step will be to weld the aft bulkhead, forward bulkhead, and wing box to create the main triangular structure of the fuselage frame. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598350021784-W4XQJOF0M27KFV7XDIVD/IMG_20180301_094403384-Large.jpg Blog - Fuselage Frame Progress Landing gear box assembly with lower aft keel pocket in place. This will not be welded until the keel is ready for installation. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598350035622-9BRIVIGU54Z9738CG5I9/IMG_20180301_094425674-Large.jpg Blog - Fuselage Frame Progress Landing gear end of forward bulkhead. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598350048641-YJHR3POC9X9DCLSWXBK2/IMG_20180301_094449563-Large.jpg Blog - Fuselage Frame Progress The main spar tube is for fitment purposes only. The forward bulhead will be welded to the main spar tube that is already part of the wing box. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598350059865-IWPV6T255KEMY56PHTSO/IMG_20180301_094717490-Large.jpg Blog - Fuselage Frame Progress Completed forward bulkhead. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598350069055-N9KIKPR08D1K91YC13Y8/IMG_20180304_103306877-Large.jpg Blog - Fuselage Frame Progress Landing gear box assembly placed in tooling fixture. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598350079145-YHA5OOP8FVL2OU7YY33N/IMG_20180304_103357983-Large.jpg Blog - Fuselage Frame Progress Landing gear box assembly ready for welding. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598350099459-NOAWIUNBSALHCCX8XH1E/IMG_20180309_103244212-Large.jpg Blog - Fuselage Frame Progress Boring the holes using the mill. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598350109694-5CFJLGWWA4PYZ8SYUIN0/IMG_20180309_165230020-Large.jpg Blog - Fuselage Frame Progress Close-up of the instrument panel mount tube. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598350120129-OTZPH8GOMXWSKDA4FZEH/IMG_20180309_165241826-Large.jpg Blog - Fuselage Frame Progress Instrument panel assembly fitted in the tooling. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598350131969-782GS1F0QC1ZIP5JAZS2/IMG_20180311_171742878-Large.jpg Blog - Fuselage Frame Progress Welded instrument panel and landing gear box assemblies. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1598650878189-85RZJVA2O3ZXKEHKSSU0/InstPnl_tooling-1.jpg Blog - Fuselage Frame Progress We designed and 3D printed tooling to help get the correct placement and angle of the mount tube holes. https://ehawk.iolani.org/blog/distance-learning monthly 0.5 2020-10-23 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1599444407375-RDF1VBD6UA0OEMYHUXXE/zoom+call+1.JPG Blog - Virtual Progress https://ehawk.iolani.org/blog/motorbattery-instrumentation-display monthly 0.5 2022-04-29 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1601599012358-UIY8PESQO39S7WZ2VKZR/PXL_20201001_212808716.jpg Blog - Motor/Battery Instrumentation Display Programming using PlatformIO. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1601584608568-6ASWYVCQJYOC9I44G5RB/Instrumentation+Final+V2.PNG Blog - Motor/Battery Instrumentation Display Final battery instrumentation display layout. A great feature of Adobe Illustrator is the ability to create a canvas of any desired dimension and move elements to specific coordinates with ease. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1601599225075-799IFGS5YK0YDMFM4FL2/PXL_20201002_003846608.jpg Blog - Motor/Battery Instrumentation Display Wiring for the display and CAN bus transceiver. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1601584874767-2VHKXORKTSA5KBEY25DV/IMG_1054.jpg Blog - Motor/Battery Instrumentation Display Battery instrumentation display in its shroud. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1601584922991-503K8KXKKESMKS8E3CAM/IMG_1055.jpg Blog - Motor/Battery Instrumentation Display Up close view of battery instrumentation display, currently a 480x800 pixel 5” TFT display. https://ehawk.iolani.org/blog/end-of-the-quarter monthly 0.5 2022-04-29 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1603495088844-W2ST9Q9MDQ1RL9D69P8I/EHawkTeamPic.jpg Blog - End of Quarter 1 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1603494184673-QO9QP3MHRUM8EFWC3OVW/ProgrammingBehindShot.jpg Blog - End of Quarter 1 As part of researching different ways to display sensor data, I examine example code from public repositories. The code in this picture gave me the idea of averaging the received data. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1603494159886-BALVG9KN7MGNOP99YL9F/SensorSetup.jpg Blog - End of Quarter 1 This is the setup I used for the initial testing of the DLVR sensor. The sensor is wired to an Arduino Nano. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1603494196759-GXC33U9F9YX74SNNV8M6/ProgrammingPic.jpg Blog - End of Quarter 1 When I first started programming the pressure sensor there was a lot of cross-referencing between forums and the datasheet! https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1603534023786-MJLN5TBR1MEEMJDR9O5N/JonahSchematicMaking.jpg Blog - End of Quarter 1 Working on the wiring schematic for the motor controller and display monitor! https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1605895349989-18XBW81YARJI1358EGT0/PXL_20201105_201859654.jpg Blog - End of Quarter 1 Breadboard prototype has been migrated to a perfboard. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1603481465589-G9QZ8JG0U9ORIEZYU4UW/Oratex+Glue+application.jpg Blog - End of Quarter 1 Here, I am applying heat-activated glue to the fabric that will be adhered to the test piece. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1603481434982-K1MWI3YKFH2FCOOBC0TN/Oratex%2Btest%2Bpiece.jpg Blog - End of Quarter 1 The test piece allowed me to experiment with the Oratex fabric application. The wrinkles on the test piece were likely because the piece was relatively small and had numerous ridges. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1603481739629-L87SI0OEPJR34S67KZFL/prepped+HS.JPG Blog - End of Quarter 1 Here is what the horizontal elevator looks like after acid etching, applying a conversion coating, and spraying the surface with Zinc-Chromate primer. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1603481175725-RJSUBA85JCIN2N8BH7LG/Oratex+eating.jpg Blog - End of Quarter 1 The Oratex glue is heat-activated. To adhere the fabric to the structure, I used a heat gun while carefully stretching/pressing the fabric down. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1603481175125-9LMNTASKI7KUBU274KST/Finished+HS.jpg Blog - End of Quarter 1 Here is the completed horizontal elevator! Heating the fabric with an iron removes most of the wrinkles and tautens the fabric. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1603482249057-56PPXZUF6JDNJA6ZAPN3/instrument+panel.jpg Blog - End of Quarter 1 This is the current design for the instrument panel. https://ehawk.iolani.org/blog/quarter-3-blog monthly 0.5 2022-04-29 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1608515935535-P56BEC863ZM4UDIZ9DKB/Altimeter_Neutral.jpg Blog - End of Quarter 2 The altimeter set-up and TFT Display. Right now there is no change in altitude, so the bar is not shown. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1608515862722-6OKHMO8JDCDPMNXFBSTK/Altimeter_Positive.jpg Blog - End of Quarter 2 By changing the QNH, I changed the altitude to emulate rising altitude. We can see that there is a green bar now on the right. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1608515866564-2JZNOKUPE2RLWXBG7AYG/Altimeter_Negatice.jpg Blog - End of Quarter 2 By increasing the QNH, I simulate a downward change in altitude. We can see that the bar on the right is now red and going down from the center. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1608935223621-AGE5BBCKEZK84291AICD/Screenshot+2020-12-25+122613.jpg Blog - End of Quarter 2 Plot of logged RPM versus time, interpreted in Excel https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1608935223992-4F9GF90OGT27S6IJKG25/Screenshot+2020-12-25+122650.jpg Blog - End of Quarter 2 CAD image of the instrumentation panel and collar in assembly https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1608403527133-AMW518MZNXWM9F7W4C6K/christmas%2Bteam%2Bphoto.jpg Blog - End of Quarter 2 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1608404486096-9NL6X5I3OU8F731DC30G/PXL_20201217_162852405.jpg Blog - End of Quarter 2 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1608404485541-H35X430XC51W62D64G2R/PXL_20201217_163748308.jpg Blog - End of Quarter 2 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1608404492736-HAB1OZDC4HAJUF0SCDO3/PXL_20201217_164305575.jpg Blog - End of Quarter 2 https://ehawk.iolani.org/blog/central-covering monthly 0.5 2022-04-29 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1611985564033-VFQ3NN9PB1HMX1LOO40D/covering%2Bplacing.jpg Blog - Wing Box Covering The Dacron piece covers the open space between the two wings, and is held on using Velcro. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1611985780118-6UCFACEGKK8CAKTR4PQQ/dacron%2Bcutting.jpg Blog - Wing Box Covering The fabric was cut using a soldering iron with a modified tip. The heat melted the fabric to prevent fraying. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1611985713194-J6ZA9T2RWNTR76KQHQ7X/Sewing%2Bpining.jpg Blog - Wing Box Covering I periodically did fit checks and pinned the piece to the plane to ensure that I got rid of any slack and that the piece conformed well to the contours of the plane. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1611985749684-7K8PNRTCYQ20YUKL64BM/sewing.jpg Blog - Wing Box Covering I used a sewing machine for all of the sewing, which resulted in a cleaner, stronger finish. I also layered the fabric when I sewed to ensure greater strength. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1611985666208-PA2TBUAF77N26JDE77ZH/dacron%2Bpinning.jpg Blog - Wing Box Covering The covering wraps around the leading edge, requiring us to remove the keel tube. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1611985614560-BFGKO8OIDNZJB758GY7O/dacron%2Bplacing.jpg Blog - Wing Box Covering In this perspective view, you can see that the covering generally follows the shape of the wings on either side. https://ehawk.iolani.org/blog/fchepcs2jaazta64acwijry2gt7yv5 monthly 0.5 2022-04-29 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1617605712394-K0DD8TH2SU4570IY21E7/mpp+skectch.jpg Blog - Main Power Panel Sketching out the design outline onto a wood prototype https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1617605702829-TZ2PL0M0J8PKG8G0FABW/mpp+design.jpg Blog - Main Power Panel Using Adobe Illustrator to design the panel https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1617610072574-1OT9JQLW9TJ3SXECI3HR/mpp%2Bbare.jpg Blog - Main Power Panel The panel itself before the electrical components are assembled onto it. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1617605714300-QPKF2PSQRONUDA1LX432/mpp.jpg Blog - Main Power Panel Panel with electrical components assembled https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1617605692093-4HK2BME6QKQVO36S8GC3/mpp+back.jpg Blog - Main Power Panel Back view of the panel https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1617605693122-Z1YY0CC3CDTD6DZGNN6C/main+POwer+panel.jpg Blog - Main Power Panel Final main power panel design assembled and installed on the plane with rivets https://ehawk.iolani.org/blog/fchepcs2jaazta64acwijry2gt7yv5-8885j monthly 0.5 2022-04-29 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1619124662229-GJYUGMCA33QI77UMT3PH/B1.jpg Blog - Instrumentation Panel and Shroud Assembly The first nine design iterations of the panel in wood, with the last spray-painted. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1619124620403-4YU8HEX7IK48Z01Q2Y20/B2.PNG Blog - Instrumentation Panel and Shroud Assembly A stack of panels. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1619124624718-YYXXLF7HVUJ4NGW3VNSY/B3.PNG Blog - Instrumentation Panel and Shroud Assembly Plastic iterations of the TFT frame covers. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1619124629996-PV8R1AET6LYFEXP114A9/B4.PNG Blog - Instrumentation Panel and Shroud Assembly Two shroud prototypes. A keel holder is slotted into the right one. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1619124633355-NCN9U0UV2CYRHHBHCIHL/B5.PNG Blog - Instrumentation Panel and Shroud Assembly Shroud front piece with embedded nuts. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1619124636350-XESMGBKQ5QPJ7QOQQ07X/B6.PNG Blog - Instrumentation Panel and Shroud Assembly Perfboard prototypes and switches sticking out of the back of the panel. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1619124639831-YJJM14FV02CZIZWO5D3H/B7.PNG Blog - Instrumentation Panel and Shroud Assembly Top view of first assembly prototype. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1619124642897-68IP1RE61O2UFUCL457P/B8.PNG Blog - Instrumentation Panel and Shroud Assembly Side view of first assembly prototype. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1619124645372-MASOFP7ZZX4PBMPIKUJ6/B9.PNG Blog - Instrumentation Panel and Shroud Assembly Front view of first assembly prototype. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1619124834272-SGQHM1XTQGSPBIVU9HK8/PXL_20210311_232945279.jpg Blog - Instrumentation Panel and Shroud Assembly Embedded nuts being inserted into shroud front piece during printing. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1619124849017-ZMXXIW6H0M04V8C3BG34/PXL_20210316_022222440.jpg Blog - Instrumentation Panel and Shroud Assembly Cutting aluminum panel and cover. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1619124856596-UMXQV4Y7L47Z5SROJDXX/PXL_20210318_193624462.jpg Blog - Instrumentation Panel and Shroud Assembly Wood prototype of etching. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1619124862832-PO2UT8DT2KNLZHV9OL2O/PXL_20210329_211957966.jpg Blog - Instrumentation Panel and Shroud Assembly Taking the cover out after etching. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1619124868352-25G7SFUHQJJHD6E1F363/PXL_20210329_213009697.jpg Blog - Instrumentation Panel and Shroud Assembly Etched aluminum cover and panel. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1619124879821-WF701G90A9O0RRR39TPA/PXL_20210401_234842250.jpg Blog - Instrumentation Panel and Shroud Assembly Instrumentation panel and shroud assembly with electronics on. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1619124887105-JSF17VVI996RQMZ1274E/PXL_20210402_031617400.jpg Blog - Instrumentation Panel and Shroud Assembly Exposed electronics (before front shroud piece is put on). https://ehawk.iolani.org/blog/2021-update-video monthly 0.5 2021-06-25 https://ehawk.iolani.org/contact daily 0.75 2020-08-10 https://ehawk.iolani.org/home daily 1.0 2023-01-10 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1608401797048-GFMQ69D9EJJP2M8RDRT8/team%2Bphoto.jpg Home https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1608402240665-ABBDC2N89MKWWWPOGRYQ/sitting%2Bin%2Bchair.jpg Home - Contact Us Have questions or comments? Just want to say hi? Feel free to reach out to us! We’ll try to get back to you as soon as we can. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595361540620-Q6ARRMSOHTEYYA2YIIUQ/posing%252Bin%252Bfront%252Bof%252Behawk.jpg Home - About Us Learn more about the students, faculty, and facilities that make the E-Hawk Plane Project possible. https://ehawk.iolani.org/meet-the-team daily 0.75 2021-01-30 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1608401114280-VOM103E36OC2YRF7XTB7/team+photo.jpg Meet the Team https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1611983262982-37D0ERAMA64KQYWU0WG6/senior+page+pic.jpg Meet the Team https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596038961677-IDBO8AT0BVB8C6TX9YS9/jonah.jpg Meet the Team https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597398497731-OVT6QHOJXRQWPDRT0VYF/AILP+Photo.jpg Meet the Team https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596037059445-DJY0G8N74YUHCZ67XUQL/william1.jpg Meet the Team https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597024831660-JW40D3ALG4PEZXMLF135/braxton%2Bedited.jpg Meet the Team https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1596036961944-D27YU23ZFFJJG7V9TJWT/dylan+edited.jpg Meet the Team https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1597024752787-QUPS05SL5F3IYI9V5QNL/ethan.jpg Meet the Team Ethan has worked on the E-Hawk project off and on from 2017 to 2019. He is a very curious individual. He never settles for just accepting things as they are, he is driven by his desire to improve things and solve problems. He always enjoys the thrill of discovering something new. When he's not engaged in engineering he can be found surfing with his friends and backpacking around the outer islands. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595362114524-UC0U2Z9HO9ASO890GG97/me+and+naia+sitting.jpeg Meet the Team https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595362057397-35OWRSZ0MUOQ30BBUIFC/front+of+sullivan1.JPG Meet the Team https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595362228440-I4I3S87MAOABFVAD9RA1/the+boys.JPG Meet the Team https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595362089012-8NMO0S1O8RCJCYGIO0CM/smiling+by+wing+-+me%2C+taylor%2C+noah.jpg Meet the Team https://ehawk.iolani.org/iolani-school daily 0.75 2020-07-20 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595212422576-TPIAJ7FMQSPMWKFO8B6N/sullivan.jpg 'Iolani School - Sullivan Center The Sullivan Center for Innovation and Leadership is where most of the fabrication of the E-Hawk plane takes place. https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595212372447-UZ6B68KAAH5RNTVAAP3D/iolani.jpg 'Iolani School - ‘Iolani School ‘Iolani School is where this entire project began; just a handful of students and their teacher, hoping to build an electric-powered plane to promote sustainable flight! https://ehawk.iolani.org/emg6 daily 0.75 2023-01-10 https://images.squarespace-cdn.com/content/v1/5f14c8ac4b5f222b2a4d567b/1595257755031-0NAKI28GVZNNRJUR3QD3/emg+6.jpg EMG-6 https://ehawk.iolani.org/videos daily 0.75 2024-04-25