Introduction: Airplane Arno Horion

This is how you make the AHA

Step 1: Step 1: Shaping the Fuselage

Materials needed:

- Insulating foam (PUR)

- Small handsaw

- Rasp file

- Sanding paper

Start with drawing the design of the airplane on the foam, the drawing shows an example of a design, but you are free to choose the design as long as it's in the same style as the example.

If you're done with the rough forming of the fuselage, you can start by rasping the material to form a cockpit as you see it on the drawing. After this is done you can refine it by sanding it with a light sanding paper.

Then you can shape the place where whill get to be placed, just give it the shape of half a drop (this is the profile the wing will get to create lift). Ensure that the wing is approximately as wide as the half of length of the fuselage.

Step 2: Step 2: Making the Wings

Materials needed:

- Depron or kadapak (both 3mm)

- Hobbyknife

- Balsa beam (5 mm)

- Foam (PUR)

- Foam safe glue

- carbon tube (outer diameter 4mm)

- Oracover or sticky foil

- Drill (4 mm)

- Foam (PUR)

To start building the wing, you have to cut out the ribs of the wing. The first of the ribs has the same shape and size as the wingseat on the fuselage, so you can simply draw it over onto the depron / kadapak. Also think about the fact that you have to make each rib 2 times. To make the other 3 ribs you can just take the shape of the first rib and just reduce the size 5 % per rib. After that you make a square hole of 5 mm at about 1/3 from the leading edge in all of the ribs. Also make a gap of 8 mm deep and 3 mm wide into the leading edge.

Then you take a balsa beam of 500 mm in length, en you place it like in the drawing. Then you take the ribs and place them on the beam vertically at about 100 mm from each other, then just mirror it to get the other side of the wing. Next you get a piece of depron / kadapak of 8mm wide and 500mm long and you place it in the gap on the front of the ribs. Ensure that the ribs stay vertical.

Now we're gonna place the carbon tube, it doesn't have to be placed on a measured distance as long as it fits trough all of the ribs, and it has to be the same on both sides of the wing. You can fit it into the ribs by drilling a hole at the place where the tube is gonna sit. Make that the tube sticks out of the first rib (fuselage side) for about 60 mm.

At last you should fix everything in its place by using the glue.

To make the tip of the wing you just shape a piece of foam so it blends in to the wing.

The last step is placing the film onto the wing, do that so the foil is reasonably strained.

Step 3: Step 3: Build the Tail

Materials needed:

- Carbon tube ( 6 x 4 mm)

- Depron (3 mm) or Foam (PUR)

- Foam safe glue

Take the depron and cut it to the shape of the first drawing, you can choose the size of it (if you're using the PUR you sand it untill it has a maximum thickness of 5mm). Mirror it to get the other side. Next you glue the two pieces together like on the second drawing.

Then you take a piece of carbon tube with a length of about 500 mm and you glue the assembled tailsurface on the end of it.

Step 4: Step 4: Prepare the Fuselage for Assembly

Materials needed:

- Aluminum tube (6 x 4 mm diameter)

- Hobbyknife

- Foam safe glue

- (Glass fiber + epoxy)

- Putty

- Sanding paper

Cut the aluminum tube so it's as long as the fuselage is wide.

Foresee the gaps like in the first drawing, and make that the vertical gap is as deep as half the thickness the fuselage and the horizontal is as deep as half the thickness of the wing profile. Also supply a gap in the nose of the model (see drawing).

The vertical gap is placed dead center and the horizontal about 1/4 of the length of the fuselage.

Make a piece of wood in the shape of th second drawing, and ensure that the rectangular top has a maximum height (the gap needs to be at least as deep as this height) as high as the thickness of the fuselage. Don't make the piece to heavy but foresee a hole in it so you can add weight afterwords. If that is all done you just glue the wooden piece in place.

Then glue the aluminum tube in place in the horizontal gap.

Take the assembled tail piece and glue it into place, ensure the tail to be aligned with the fuselage.

The last thing you have to do is filling the gaps with the putty and sanding it so its even with the surfaces of the fuselage.

An optional thing is strengthening the fuselage with glass fiber.

Step 5: Step 5: Assembly

Pieces needed:

- 2 wing halfs

- Fuselage + tail

Materials needed:

- Rests of the 4 mm carbon tube

-Foam safe glue

- 4 mm drill

Take the wings and place them in the aluminum tube in the fuselage. Then ensure that the wings are completely horizontal and mark the place where you are gonna place the carbon tubes (close to the leading edge). Drill a hole in the fuselage and in the wing where the carbon tubes are going to sit. At last glue the carbon tubes in the holes.

Now all of the pieces are complete and you can assemble the airplane.

Just slide the wings in to the aluminum tube and the carbon tube pieces.

Comments

author
rimar2000 made it!(author)2014-05-19

Nice design.

author
IDArnoHorion made it!(author)2014-05-20

Thanks

author
Danger+is+my+middle+name made it!(author)2014-05-19

Awesome job, how does it fly?

author
IDArnoHorion made it!(author)2014-05-19

It flies pretty good. With a light wind ahead and a good throw you should get more then 20 metres.

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