MrBens Zephyr XL Build Log

[MrBen]

First job sand down wing join and glue together, UHU Por on the surface and CA glue on the crack afterwards




Next I need to enlarge both the front lipo bay and the rear RVOSD bay you can see the difference between stock size and enlarged size on the next 2 photos







The very front of the lipo bay will be completely cut away later once a new battery bay/cam box has been made from ply, this will run right through to where the nose of the aircraft currently is and will be one piece. I will line the floor of the RVOSD rear compartment with 1mm fibre glass sheet

[MrBen]

Next step to join the wing halves and add the main spars



There are 2 spars stacked in the groove, the first is CA'd in place then coated with a line of gorilla glue which is then activated with water, next the 2nd spar goes in on top of the GG and held in place with loads of T pins, be careful at this point as it can easily start pushing the spar out of the slot! The T pins did the job and held it firmly in place



Once the GG has stopped expanding I removed the pins and added some more GG to fill the void



And once it is 80% dry it can be trimmed off with a sharp knife

[MrBen]

Now I added 2 spars on the top fore and aft of the back bay

[Martink1974]

looking good

[bigMouse]

Just a result of some searching, Take it with a pinch of salt, I have no first hand knowledge of the stuff!

Warning about using 3M77

[url]http://fpvlab.com/forums/archive/index.php/t-179.html?s=ee26390ee478688454ba9341b1ba9b49]http://fpvlab.com/forums/archive/index.php/t-179.html?s=ee26390ee478688454ba9341b1ba9b49]
[url]http://fpvlab.com/forums/archive/index.php/t-179.html?s=ee26390ee478688454ba9341b1ba9b49[/url]

Suggested replacement for 3M90
http://www.loctiteproducts.com/p/a_cntct_high/overview/Loctite-Spray-Adhesive-High-Performance.htm

Might be able to get that locally, save postage...

[bigMouse]

Think I might go with 4 servos, Borrow them from an old f3J . They are hs81mg's

Ben, Are you going to paint the foam or add vinyl over the Lam?

[bigMouse]

Just received mine Ben, thanks for your efforts!

Will go with the OS 750kv choice, need to make it quiet as possible, 3, 4S Haven't decided yet, will try both...

[MrBen]

Cant find that loctite 200 anywhere in the UK, Just ordered some more tesa although I'll do lighter coats this time so I dont get any pitting, gonna send the 3m77 back.

http://www.amazon.co.uk/dp/B002BDPI8I?tag=tesa0a-21&camp=1406&creative=6394&linkCode=as1&creativeASIN=B002BDPI8I&adid=0EQGKJ71G10R1KH623N6&&ref-refURL=http%3A%2F%2Fwww.tesa.co.uk%2Findustry%2Fspray-glues%2Fextra-strong-glue%2Fextra-strong-spray-glue%2C2488081%2C1.html

Also ordered a selection of props to try with the OS 750

 APC 11x7 Thin Electric Prop
 APC 11x8.5 Thin Electric Prop
 APC 12x6 Thin Electric Prop
 APC 12x8 Thin Electric Prop
 APC 13x6.5 Thin Electric Prop
 APC 13x8 Thin Electric Prop

[bigMouse]

I haven't found a source either! Can't believe that spray glue is so elusive!

[MrBen]

Motor mount gorilla glued in place



Prop opening enlarged to 13.5"



Servos moved to new forward wider location, all old servo holes filled with foam/gorilla glue. Everything has had a coat of light weight filler too.



VTX bay, UHF rx bay both cut into wings and cables running to centre compartment, wing joint and spars filled.

[MrBen]

Camera bay box made from 6mm ply, needs covering black or painting. Weighs 60g



Wing all laminated in 125micron laminate, wings were sprayed with Tesa extra strong spray glue first



RVOSD fitted, shielded wires running from VTX, that black wire is the ground for the shield, microphone on this bird too.



Getting there now, still got to add cam wire, ubec and esc, also add battery box from 3mm ply



At this stage it seems to balance ok with 3x 4s 3300mah in battery bay, thats with the OS 750KV motor in the outboard position, thats a 13" prop on her too.

[mark1975]

Looking very nice a sleek.

[bigMouse]

Looking nice Ben!

[MrBen]

Cheers guys, will try and get it ready for a weekend maiden

[brodjackella]

nice job on the camera box..