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Scratch built Foam Stinson

Old 12-15-2011, 08:49 PM
  #1  
7car7
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Default Scratch built Foam Stinson

Started a new plane I thought I'd share.
It is Loosely based on a Stinson SR-6, but will have several changes for the sake of lightness and simplicity.

My original intent was to make a simple plane for my kids to fly and learn on. They've flown some of my other planes on the buddy box, but they either have a lot of time invested in them, or are pricey, or are just too aerobatic/fast for beginners.

I chose this basic plane because I wanted something that looked like an airplane (not a fan of flying sticks), yet be a "trainer" style layout.
Also, I wanted a plane with a radial style engine, for easy cowl construction. Only problem is like everything I do, I make it more fancy and stylish than is needed.

This one will be very light, and of a pretty good size, and intentionally underpowered.

Wing span will be appx 45", and I'm shooting for a total weight of about 12-14 ounces.

I just found a 3 view, printed it out (much smaller than the actual model), and just started drawing on butcher paper.
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Last edited by 7car7; 12-15-2011 at 10:57 PM.
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Old 12-15-2011, 10:53 PM
  #2  
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Very nice! What kind of foam are you using? It looks like it is molded in that color.
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Old 12-15-2011, 10:59 PM
  #3  
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Originally Posted by earthsciteach View Post
Very nice! What kind of foam are you using? It looks like it is molded in that color.
Thank you! It is just black depron sheet. Got it at the hobby store about a year or so ago, they were out of white.

I could be wrong, haven't played with the white stuff lately, but it seems that the black is easier to get a bend out of. Acts more like meat tray foam than white depron.
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Old 12-19-2011, 05:57 PM
  #4  
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Some more progress on the Stinson.

It's gone through a bit of a change of plans since my last post.
I removed and re-built the whole top section, and the way the access to the inside works.

I also remembered I had some GWS Cub wings that I bought a couple years ago. I bought two sets, thinking I was going to do a scratch bipe or something. Well, I dug them out of the box, and they were perfect for an SR-6, and perfect size for this plane. I just know I can't make as nice of wings as light as these without making some sort of a mold to press the Depron.

I also re-modeled the nose cowl mold. The original was just a little tight. I added some foam around the mold, put epoxy resin on it, and added 18 strips of wood to simulate the bulges. The soda bottle cowl was an absolute PAIN to get off the mold with those bulges.
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Old 12-21-2011, 07:38 PM
  #5  
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Default Landing Gear

Got the landing gear figured out.

Goal here was to make it easily removable, so I can put on floats in the future without having to mod it.

It is made with 1/8th OD aluminum tubing, set into wood blocks inside, and passing thru Popsicle sticks on the fuse sides to keep the foam from ripping.
Piano wire legs will be made that get pushed into the tubing.
As can be seen, there is a 3rd tubing section to the rear - that will be for the extra leg that the floats use. I didn't want to have to cut the plane up later for that. I figured design it from the beginning to be a sea plane, and all will be good!

As with any landing gear, it makes up a significant amount of the model weight, but I'm happy it didn't add much, and it is going to be strong without having to worry about it getting messed up later on.

Fuse is now at 3.2oz.
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Old 12-24-2011, 10:57 PM
  #6  
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Default Wing struts

Working on the wing struts. They are 1.5mm carbon rods. Made a block of foam to glue them into on the wings, and they plug into quick connects attached to the landing gear tubing outputs. Plane is at 5oz, with no gear. Going up, but I'm very happy. It is 44" after all.
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Old 12-25-2011, 01:55 AM
  #7  
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Good to see you scratch building this plane from foam the old fashioned way, especially when it's so easy for folks to just ARF them, since HH makes the plane now.
BTW, those little aileron clevises are handy. I have yet to use them, for what they're intended for.
They're used on the strut-to-wing mounts on the plane below.
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Old 12-25-2011, 03:29 AM
  #8  
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Originally Posted by Bill G View Post
Good to see you scratch building this plane from foam the old fashioned way, especially when it's so easy for folks to just ARF them, since HH makes the plane now.
BTW, those little aileron clevises are handy. I have yet to use them, for what they're intended for.
They're used on the strut-to-wing mounts on the plane below.
That is one awesome build Bill!
Check out this method for blisters...
http://www.rcgroups.com/forums/showp...2&postcount=34
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Old 12-30-2011, 08:33 PM
  #9  
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Default landing gear

Have the gear just about squared away, and the rudder.

Gear is not feather weight, but I wanted a scale look that wouldn't break. And it's easy to remove for floats.

The rudder/vertical was made from 2 layers of depron, and they were tapered with sandpaper on the inner surface before laminating with a thin skim of gorilla glue.

Elevator will be a challenge, will have to be 2 halves, since the rudder is mounted to the vertical already. it was easier that way since the tail wheel was set inside, and I wanted the CA hinges to be secure with the tail wheel wire.
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Last edited by 7car7; 12-30-2011 at 08:56 PM.
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Old 12-30-2011, 09:00 PM
  #10  
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Default Laminating the Elevator

Had a bit of trouble when I glued up the horizontal and elevator. I didn't get quite enough glue on the edges and they lifted after I removed the tape. So I put some more gorilla glue on the edges that lifted and retaped them, but I learned a bit of a new method.

Before, I was using individual strips of tape all the way around the edges. It was very tedious to remove all of that tape afterwards.

This second time around I used a long piece of tape on each side and then pushed it together after the glue was put on the edges. I then folded those 2 pieces over and taped them down and then again added another strip of tape on each side and then squeezed that together with my fingernails. That second layer squeezed together is needed because the first layer gets wet with glue and will not stick to each other.
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Old 01-03-2012, 09:30 PM
  #11  
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Default Wheels done, on to PAINT!

Ah, Christmas breaks are great for plane building! Lots of progress.

Wheel pants came out great. They are held on with a tiny Rare Earth Magnet. They're able to rotate if impacted.

I'm now in paint stage!

I first coated the plane with Water Based Polyurethane (WBPU). I mixed in Talc Powder to act as a filler. I'm using WBPU out of a can - the brush on type, not spray. The fuse gained about 3-4 grams after it was dry. It's very light stuff.

Then I sprayed with a light coat of black Testors. The black makes it very challenging to get a good picture now.

I also sprayed the wings with Testors Gloss yellow. A much nicer look than the original greenish yellow of the GWS wings.

Still all very well under 10 ounces, so I'm really happy about the weight.
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Old 01-05-2012, 05:37 PM
  #12  
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Default Wing Painting

Put some Lettering on the right wing in the scale location for an SR6, along with the curved 2-tone the original has.

Made a stencil from paper, ran it thru this cool little machine my wife has for scrapbooking. Puts sticky back on paper, and I use some that's considered re-positional and temporary.
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Old 01-06-2012, 03:13 PM
  #13  
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Got some yellow paint on the fuse. What a tedious deal that is. Lots of masking tape and newspaper. Brushing would be easier.

Because the yellow is so translucent, I sprayed on a coat of Testors Flat White first to act as a primer. Worked great, no black came through.

Trying to decide if I should do the elevator/horizontal in the yellow stripe too. Probably should, the real ones seem to all have it.

Now on to the cowl and sides of fuse.
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Old 01-09-2012, 06:14 PM
  #14  
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Default Stripe Painting

Got the pin-striping done. Also the windows.

Now on to the motor and servos.
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Old 01-09-2012, 07:08 PM
  #15  
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Just discoverd your build and am really enjoying it. Nice choice of airplanes and really nice work.

Thanks for sharing.

ce
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Old 01-09-2012, 07:20 PM
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Thank you Capt! Really a fun build. Getting really excited to see it fly, but even more excited to eventually get some floats made for it.
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Old 01-09-2012, 10:33 PM
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Originally Posted by 7car7 View Post
Thank you Capt! Really a fun build. Getting really excited to see it fly, but even more excited to eventually get some floats made for it.
Your'e welcome - that's going to ba a fun plane...
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Old 01-09-2012, 11:39 PM
  #18  
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This looks great. Best of luck.
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Old 01-10-2012, 12:26 AM
  #19  
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The color you have chosen for the decal windows looks good. You obviously couldn't have gone with black,
in order to have any contrast, but either way the color has a nice effect.
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Old 01-10-2012, 12:42 AM
  #20  
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Thanks Bill, it was sort of a dilemma, but I'm happy how it came out.
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Old 01-13-2012, 06:59 PM
  #21  
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Default All Done, and Maidened!

The Stinson is done, and it flew really well. Very easy to fly, and very responsive. Almost too responsive. Even on low rates, it turns on a dime.

Being that it's a 3 channel with no ailerons, it has a tendency to roll around a bit. I came away feeling that I will most likely do a nice lightweight single servo aileron setup eventually. But it's not "needed", it would just give a more scale flight, and easier landings.

It needs a bit of up elevator trim to fly level, which is disappointing. I moved the battery back to the 33% area, and if flew great, but still needs up elevator. Not sure what's going on. Needs more testing. It was getting dark, so just 2 flights with 2 batteries. The 1300 lasted a long time, as did a 9xx.

Not sure I mentioned earlier, but I ended up going with the larger GWS 350 geared brushed motor, instead of the original planned IPS geared motor. A good decision. This plane is NOT fast, and does not climb super fast, but it's more than adequate for it's intended purpose.

Overall, very happy, just needs some mild tweaks.



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Old 07-12-2012, 06:42 PM
  #22  
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Default Floats

I built this plane from the beginning to be able to easily put on some floats. The standard landing gear plugs into the fuse into some tubing, but I noticed that the full scale plane has it's rear float legs attaching at a spot more rearward than the regular gear. So I had added those extra tubes for future floats.

Float construction has begun. They're going together very quickly.
I started out with a nice side view of a Beaver on floats, same style flat top floats as the Stinson uses.

I traced over the picture with a drawing program, scaled it up until it was the right size, then printed it out with refference marks to line it up after printing. They're 20 inches long, paper is 11".
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Old 07-12-2012, 09:30 PM
  #23  
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Really nice!
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Old 07-22-2012, 06:26 AM
  #24  
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The paint really sets it apart. Very well done.
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Old 07-25-2012, 04:01 PM
  #25  
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Thank you!

I need to get an update I guess. Floats are almost done. The struts, and how they attach, and all the angles of them - very time consuming.

Did a float test last night, I wrapped saran wrap around them, since they're not sealed up yet. Floats great. Only concern is the angle of the plane - leans back a bit, might have to adjust that.

edit- adjusted the angle a bit. Raised up the rear of the plane on the mounts a bit.

Last edited by 7car7; 07-30-2012 at 08:57 PM.
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