NELSON Hobby Direct
Mailing Address: PO BOX 1327
Keller, TX 76244 USA
817-431-9898 / 877-263-5766 / FAX 817-431-6436

NEW
PRODUCTS

Balsa Wood

Great Lakes
Biplane

Precision Scale
Instruments


Aircraft Kits

Aeronca 7AC
Champion

Bellcranks

Cable & Cable Accessories

Clamps & Squares

Clevises

CNC Servo
Wheels &
Arms

Epoxies

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Film Covering

Fasteners

Flying Wires

Glow Drivers

Model Drawings

Paint

Paint Spray Units

Piano Hinges

Pushrods

RC Linkage
(Rocket City)

Servo Arms

 


Product Instructions



PRODUCTS
FROM OTHER
COMPANIES

Fourmost Products

Pinking Tape and
Covering Acessories

ProSpark Ignition
Systems

Sherline Lathes & Mills

System Three Resins

(more to come)


FLYRC Magazine

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 



Great Lakes Biplane will be first kit. More informaiton in this section.

Aeronca 7AC Champion

A R/C miniature aircraft in 30% scale

Full scale Aeronca 7AC taken at the 2004 McMinville, Oregon fly-in. This aircraft is in excellent condition and is unique in that it has wheel pants and paint trim on the leading edge of the wing and stabilizer. This aircraft is based in Canada.

November 21, 2007

Even though I still don't have a compete airframe, I have received several orders (13) for an Aeronca kit. I am not taking any deposits or payments until I have flown the prototype. If the prototype is performing as expected, and I have finished updateing the drawings, then $500 deposits will be taken.

I am very encouraged with the response for the project. Thanks to all of you have showed interest and words of encouragement. And, especially those who have said they will order a kit when the kits are available.

Haven't had much time to work on the project lately. As of today, November 21th, the stabilizer and rudder are made. The fuselage is basically done with a scale door and sliding windows, as well as the landing gear. Some of the cockpit details need to be finished. Major items to complete the fuselage are the scale gas tank. Canopy mold won't be made until the wings are fitted to the fuselage.

The elevators are next. No problem making them since they are built similar to the rudder. When the elevators are in place then I can finish up the elevator push rod linkage and the pull pull linkage for the rudder.

Wings   and wing struts are the last items. Pretty simple construction other than the ailerons. Ailerons will be made out of aluminum. Shouldn't be any problems, but you never can tell if problems could occur.

Again, thanks to all of you with your interest and support of our Aeronca project.

Jerry Nelson

"AERONCA CHAMPION PROJECT

ON HOLD"

Great Lakes Project is now in process.

Recent development information. Nov 21, 2007

(30% Great Lakes Biplane 2T-1A Project)

 

1980 production Great Lakes 2T-1A Biplane. 180 HP Lycoming engine. Wingspan is about 27 feet. Smaller than a Waco and bigger than a two place Pitts Special. Double ailerons and inverted fuel/oil system. Fully aerobatic for advanced aerobatics. The bubble canopy was custom made.

Photo of another 1980 Great Lakes 2T-1A biplane in flight. Classic biplane look with swept back top wing, two place open cockpit, and wheel pants. A Pitts type cowl makes this classic aircraft look just like it was made today. Hundreds of photos of the Great Lakes are available on the internet. Search for Great Lakes Biplane, or Great Lakes Biplane 2T-1.

 

As of May 2007, I haven't had the opportunity to work much on the Aeronca project. Main reason is spending my spare time learning how to operate a three dimension (3D) CAD drawing software. The software is a professional type suitable for any advance mechanical engineering project (oil refineries, airliners, boats, bridges, automobiles, etc.).

I have progressed rapidly learning how to work with the 3D software. I consider my skill level at this time to be an advanced student at a 70% skill level. I am learning more about the software every time I work on my drawings.

I have been learning the process by making the drawings for my 30% scale Great Lakes 2T-1A biplane project. For reference, I am using original factory production drawings. Can't get much more scale than that. Almost all of the full scale Great Lakes structure design is being used in our scale model.The Great Lakes was to be my second kit. It will now be the initial kit.  The reason for the change is for format and the producing the instruction manual.

For the instruction manual, I will be able to provide a photo type or a line drawing illustration of any part or assembly including step by step assembly drawings. The software is really amazing. In general terms, a very complete instruction manual with hundreds of illustrations orientated in any view and what ever detail that I want to show can be made without ever making an actual part.

Corrections due to errors, problems, or change in design can be accomplished. Sometimes easily, other times with some difficulty. But the changes can be made as necessary.

I also know what the actual weight will be for the parts, sub assemblies, and weight of the completed aircraft. Even can know where the center of gravity will be.

I am about 3/4 finished with the Great Lake drawings. In a few weeks I should be able to start making the tail group items here at my shop while working on the rest of the drawings at home. The bulk of the instruction manual (the illustrations) is automatically done while the drawings are created. Shop or working drawings are automatically made. All I have to add to the shop drawings is the dimensions and notes if appropriate. A complete bill of materials is automatically created as well.

I think I can produce a prototype Great Lakes model and more importantly, a rough draft of the compete instruction manual in less time than I can finish the Aeronca project and then finish the drawings and instruction manual.   After the Great Lakes kit is available for purchase, I will redraw the Aeronca in the 3D format. Fortunately much of the 2D AutoCAD drawings that have been completed for the Aeronca can be modified with the 3D Cad system. Also I have come up with some ideas for the Great Lakes project that can be incorporated into the revised Aeronca project.

Also with the 3D redrawn Aeronca project I will be able to reengineer the Aeronca into a Citrabria or Decathlon.

Great Lakes T2-1A Biplane Specifications

The 30% model will have a 95 inch wingspan. Fuselage length about 72 inches. Scale metal tubing construction like the Aeronca. Front portion of the fuselage will be pre made from silver soldered steel tubing. Power to be Saito 300 twin to a 80 cc twin. Weight about 35 pounds. (Guess on weight at this time).

Gas tank will be in the upper wing center section. Cowl will be from aluminum sheet and fiberglass. Will have full cockpit detail including twin seats, twin control sticks, working twin rudder petals, and two instrument panels. The incidence of the stabilizer can be changed in flight by a servo. A baggage door is on the left side of the fuselage. The baggage compartment will be used for R/C equipment. Swiss made scale Aero Scale flying wires and a Sirius scale tail wheel are featured.

A unique wing panel/flying wire disconnect system is featured. I expect to be able to assemble or disassemble the aircraft at the flying field in less than 15 minutes. Only tool needed will be a 6-32 ball wrench and small phillips screwdriver.

With a 80cc twin, the aircraft should be capable of excellent vertical performance. As in the full scale aircraft, the model will be fully aerobatic designed for advanced aerobatic maneuvers.

Our Great Lakes will also be redesigned for use with a radial engine. The smaller size RCS 5 cylinder will be perfect for this aircraft. The firewall will be designed to handle the 8 pound weight of the RCS 5 cylinder engine. The Robart and Sidel 7 cylinder radials could also be used. The model can also be used with the new OS 4 cylinder inline twin or many 50cc singles mounted either upright or inverted.

So, we can have a 1930 inline engine version that will have modest aerobatic performance, a 1940-1970 modified radial engine version, or the 1980 modern version that should be abled to do vertical snap rolls. Other than the double ailerons on the 1980 version, all the aircraft engine variations are the same from the firewall back. The cowls and stringer fairing strips on the fuselage are different depending on the engine cowling.

More info to follow, time permitting. Will have a separate section on our web site for the Great Lakes project.

There are hundreds of photos for the Great Lakes on the internet. Search Google for Great Lakes Biplane, Great Lakes 2T-1, Great Lakes 2T-1 Biplane.

 

Details and Progress Report

The Aeronca 7AC will be our first kit (now changed to second kit). It will also be the first giant scale RC kit of its kind. Not only will our kit feature an exact scale outline, it will also be have a scale structure. I have excellent reference material including full scale CAD drawings of the complete aircraft. Even down to the number of screws that hold the wing tip navigation light bracket in position.

The structure will be extremely scale. Yes, there will be a few minor changes, but these changes will not be significant. The fuselage and tail group will be made from aluminum tubing and epoxied together using our MetlWeld epoxy. The wing structure will be scale except that the ribs will be made from Light Ply instead of the scale formed aluminum ribs. We could do aluminum ribs, but the cost will be very high to do so. Just not practical to make aluminum ribs.

Power for the "Champ" can be several choices. Ideal choice would be an OS Pegasus 4 cylinder 4-cycle flat four engine. A OS or Saito 300 twin is also an excellent scale like engine choice. I plan to use a DA50 for the prototype. A Zenoah G-62 would be a good choice too.

The CAD plans are about 3/4 done. Basic drawings are done, just lots of details to finish. Haven't worked on the project for about a year due to my move here to Texas. I am spending every available moment (mostly evenings) working on the drawing and making tooling for some of the parts. I estimate there will be over a 100 drawings. Every part will have a drawing, plus there are assembly drawings, and tooling/jig drawings as well. Some work has started in the detailed instruction manual. The manual will be in a three ring binder that will allow updates to the drawings as they occur. Estimates of retail prices are only given at this time.

The rudder frame is made entirely from aluminum and joined with MetalWeld epoxy. Rudder is 16" high and only weighs 2 1/2 ounces. Spar is 5/16" 6061T-6 tubing. Ribs are .016" thick 6061T-6 sheet. Trailing edge is 1/8" 5052-0 tubing. Small 1/32" aluminum gussets are used to reinforce epoxy joints.

The stabilizer frame is also made entirely from aluminum and joined with MetalWeld epoxy. Both stabilizer frames are the same. The stabilizer section shown is 16 inches in span and only weighs 2.9 ounces. It is so strong that one cannot bend or twist the unit with two hands. Leading and trailing edges are 5/16" 6061T-6 tubing. Ribs are .016" 6061T-6 sheet.

June 5th: This is the fuselage jig base. It is made from 3/4" particle board. The aluminum fame is made from the bottom up due to the triangular shape of the rear portion of the fuselage. A drawing of the bottom of the fuselage will be attached on top of the jig. The rearward portion of the fuselage about the end of the rear window tapers upward, thus the angled portion of the fuselage jig. Fixtures will be bolted to the jig to hold some of the preassembled bulkheads and the stabilizer attachment fittings.

June 25th. Progressing on the fuselage frame. Construction starts first on the rear portion of the fuselage. Most of the cross members still need to be added. Bottom longerons are completed as an assembly prior to adding the completed bulkheads. Weight at this stage is 20 ounces. Next step is attach the firewall bulkhead and the bulkhead at the instrument panel area. This bulkhead extends to the centerline of the fuselage. From there structure is added upwards to where the front spar attach fitting structure will be installed.

This is the stabilizer attach structure. The stabilizer is made in two half's and each half has attach pins that plug into the two cross tubes on the fuselage at this area. The jig system provides for perfect alignment. Longerons at the rear of the fuselage are from 1/4" diameter 6061T6 aluminum tubing. Bulkheads are from 3/16" 6061T6 aluminum tubing. The two cross tubes are 1/4" diameter that will accept the two 3/16" diameter stabilizer attach tubes.

Upper left is the rear wing spar attach fitting. Note that the landing gear and wing strut attach fittings are already in place on the front portion of the fuselage longerons. The somewhat rectangular fuselage shape at the cockpit area changes to a triangular shaped structure as shown in the photo. Additional cross members yet to be added. Gussets are used at most of the MetalWeld epoxy glue joints.

July 4th, 2006. Quite a bit of the forward section of the fuselage has been completed. Remaining work to be done to the main frame is mostly the 3/16" diameter braces in the rear of the fuselage and a few 5/16" and 1/4" braces in the front. The vertical fin has to be built and attached as well. It will be offset to the left 1/8" like the full scale aircraft. Several attach fittings have to be installed for the cockpit floor, entry door, instrument panel, servo trays, stringers, etc. Weight at this time is 2 pounds 6 ounces.

July 9, 2006. Completed vertical fin installed on fuselage. Some cross braces and gussets still to be added. Weight with fin and fuselage is 2 pounds 14 ounces. Still quite light for it size. Fuselage will be 74 inches long from trailing edge of rudder to the prop.

July 9, 2006. Starting to look like an airplane. Rudder and stabilizer that were built 3 months ago fit just fine. Waiting for more 1/4" tubing so I can finish the rest of the forward section of the fuselage.

July 18, 2006. Fuselage frame is complete except for a few more gussets. Additional details still needed are the floorboard and side panel attachment points, instrument panel detail, door frame, cowl bulkhead that goes on the firewall, firewall to instrument panel bulkhead cowling attach fittings, cowling attach points, throttle and brake servo attach fittings, gas tank attach brackets, and a few more odds and ends. Weight at this point is 3 1/2 pounds.

Firewall/motor mount assembly is securely attached to the fuselage frame.  Steel tube motor mount will be attached to firewall with rubber shock mounts.

Note brackets on the top rear longeron. These are the attach points for 3/32" plywood bulkheads that have 1/8' x 1/4" spruce stringers used to form the fuselage shape for the rear section of the fuselage.

1/32" Aluminum servo tray holds two elevator servos and the rudder servo. The two elevator servo pushrods will be attached to a sliding cross bar that in turn is attached to a single push rod going to the elevator control horn.

Right and left stabilizers are attached to two cross tubes. These attachment tubes are securely attached to the frame with additional gussets that have not be installed at the time of this photo.

August 13, 2006. Fuselage with firewall and instrument panel bulkhead installed. Nose is ready for cowl sheeting from panel bulkhead to firewall. One piece of .016" aluminum is wrapped around the fuselage as per the full scale aircraft. The sheeting is semi removable in that it is held in place with screws from the top to near the bottom of the sides. A brass gas tank is to be installed in the top porition of the nose in the same manner as the full scale aircraft. It will be about a 30 ounce capacity. A special twin clamp unit is used to pull the bottom of the cowl together at the  bottom. No screws are used on the bottom cowl sheeting. Scale plywood floor will be used to attach the seats, rudder petals, and control stick assembly.

Bottom of fuselage showing the aluminum bulkhead that provides the landing gear oleo strut assembly attach points. The three plywood bulkheads are used to attach the two bottom stringers. Also shown are the aluminum brackets used to hold the 1/16" plywood floor in place. Removable floor is held in place with 4-40 screws and nylon blind nuts that snap into the brackets. There is about 1 1/2" of space under the floor that will be used for placement of the receiver and batteries.

August 20, 2006. Nose cowl sheeting has been installed. Sheeting is removable (with some effort). This sheeting is held on with screws and with a clamp system on the bottom. The nose cowl sheeting is one piece, however it is actually made from two pieces that are joined together with rivets at the top. Nose the four large holes in the firewall that are for the shock mounting attachments for the motor mount.

 

Left side panel is installed. Panel is removable. The simulated throttle levers (2), the Magneto, master switch, and fuel shut off assembly located about in the top middle of the panel is yet to be installed.

August 28, 2006. Instrument panel has been made. Came out really nice. The instrument faces were photos downloaded from web sites from companies selling full-scale aircraft instruments. Look in month after next issue of Fly RC that will have my article on how to make this instrument panel. In our kit the instrument panel will be cut out for the customer and we will be able to make custom instrument panels for those who purchase our kit. Currently working on the installation of the window frames. Next will be the door. At this time not certain how the door will be made. Hope to make the inner part of the door from 1/4" LitePly and cover it with .016 aluminum. Real door is from aluminum.

October 2, 2006. Haven't had much time to work on the Aeronca. Finished all the installation of the cockpit side and rear panels and added a few gussets here and there. Did make up the servo tray assembly for the dual elevator servos and rudder servo. The two elevators are hooked to the sliding trim bar. There is no interaction between the two servos and a simple wye harness can be used requiring only one channel for operation. There will be an article on the tray in my "Workshop Column" in Fly RC.

Here is the servo tray installed in the middle of the rear portion of the fuselage. There will be an aluminum hatch cover on the bottom of the fuselage to get access to the servos. The tray can be removed by removing the rear cockpit panel at the baggage compartment area. Kind of hard to do, but how often do you have to remove the tray. The plywood bulkheads for the stringers have been done for a while. They are temporarily installed at this time while the control systems are installed. The stringers (1/8 x 1/4 spruce with a 1/8" diameter dowel on top) will be added when all the components that have to go into the fuselage structure have been installed. The stringers will just get in the way if they are installed now. Also want to paint the entire fuselage frame cream before the stringers, bulkheads, cockpit panels, instrument panel,  seats, etc. installed. 

Also need to get the wings built so that I can figure out the intersection of the leading edge of the wing and fuselage will determine how to make the canopy mold. Also there will be some brackets necessary for the installation of the gap covers between the wing and fuselage.

October 9, 2006. Over the weekend I made the landing gear. The main leg is spring loaded and has about 5/8" of travel. Spring tension is adjustable. The landing gear is very close to the scale design except there is no oleo strut installation. The main landing gear leg is 9/16" dia. 4130 steel tubing. The axle is 5/16" 4130 steel tubing yet to be installed. The parts have been silver soldered. Waiting for the arrival of Sullivan 5" wheels with aluminum hubs. The wheels are quite close to scale. The landing gear is attached to the fuselage brackets with 1/8" dia. aircraft Clevis Pins and 1/32" cotter pin retainers. There will be .016 aluminum sheet covering the the landing gear assembly. In the full scale aircraft, originally fabric was used to cover the assembly, but the fabric would get holes in it from small rocks blown into it by running up the engine prior to takeoff.

Front view showing the design of the pivoting axle assembly. Pivot points are 1/8" dia. aircraft Clevis Pins held in place with 1/32" cotter pins. Axle struts are from 7/16" 4130 steel tubing. The end fittings are machined aluminum held in place with roll pins. Note the two clamp units on the bottom of the nose sheeting. They are used to pull the two halves of the bottom nose sheeting together. When loosened you can get inside the area behind the firewall. May be helpful to check the fuel line fittings for any leaks due to harding over time.

OCTOBER 18, 2006. Photo showing the temporary installation of the fuselage stringers and window frame assembly. These items will be removed so that the entire fuselage frame (and landing gear) can be painted with zinc chromate and then the cockpit area painted cream. Still a few odds and ends of parts to be installed in the cockpit area such as; the brackets for the headliner, rudder petals, control sticks, magneto and carb heat detail, and the two seats.

 

AN INTRODUCTION

by Jerry Nelson

Dear Modeler:

I believe that there are modelers who have desired to build a full scale home built aircraft. There are many reasons why these individuals have not done so. For example: one cannot afford the cost of getting a pilots license or don’t want to deal with FAA regulations, cannot qualify for a pilots license due to medial reasons, not a large enough workshop, cannot afford or find a suitable hangar, perhaps a family member doesn't like the idea of “dad” flying a airplane that he built, and of course the actual cost of building a full scale aircraft which can easily be more than $25,000.

What I am offering is the chance for a modeler to actually build a full scale aircraft only in a smaller scale. The Aeronca 7AC-kit project that I will be offering later this year can fulfill that desire to create something really special. Not only are we building a miniature aircraft with scale construction methods, we are also going to have a R/C model capable of sport flying and one that will be competitive in major scale competitions.

The Aeronca 7AC is constructed typical of the steel tube fabric covered aircraft built from the 1930’s to today’s times. This includes aircraft such as the Piper Cub, Waco biplanes, a Stearman, or a modern day Pitts Model 12 aerobatic biplane. With minor exceptions, these types of aircraft are all built with similar construction techniques. There are minor differences as some aircraft have wood wing ribs and others have metal ones.

Available are plans to build many full-scale aircraft including the Cub, Waco, Skybolt, Starduster, Pitts biplanes and even a German Flichler Storch. Cost for plans varies from $75 to $600. Many are available in the $100 to $300 range. Information on plans for home built aircraft is available from many magazines for home built aircraft and the Experimental Aircraft Association in Oshkosh, Wisconsin.

What I am leading to is an idea to purchase my complete set of Aeronca 7AC plans to be used as a reference guide to build a scale R/C home built model aircraft from plans from a full-scale home built aircraft. The modern Pitts Model 12 biplane plans are available and it is built with the same kind of materials as the 1946 Aeronca 7AC. Full-scale plans are not drawn full size for obvious reasons. Dimensions are given so that you can transfer those shapes to plywood sheets, particle board, or even to the work shop floor. To build a 1/3 scale Pitts Model 12, you do the same thing, except you reduce the dimensions by 1/3 and put the shapes onto particle board.

The key for this project to make it practical to build an full-scale aircraft steel tube type of fuselage and tail group is an epoxy made by System Three Resins marketed under the name of MetalWeld™. This epoxy can bond aluminum tubing together with an extremely strong bond, thus allowing the duplication of a full-scale welded steel fuselage or tail group with the use of aluminum tubing that is glued together with the epoxy.

Materials used to build these types of aircraft are readily available from suppliers for the home built aviation industry. Prices are reasonable for materials such as aluminum tubing and sheet. My complete set of plans and instructions also +provide the sources for materials that are not commonly available in the R/C hobby industry.

My Aeronca 7AC engineering drawings were started in late 2004. Project was put on hold for the most of 2005 due to my move to Texas. I have actively been working on the project from February 2006. I expect to have a prototype flying by the end of summer 2006. Kits should be available late in 2006. Price for the kit is not certain at this time, but would expect it be about $2000. Everything will be included, even the fabric and paint. Many components will be partially assembled and ribs and formers will be finished.

I have contacted a company in Mexico that can provide me with the major components (wing, tail, and fuselage) already assembled. The idea of the assembled major components is to be able for the modeler to finish the assembly of the model without the need of any special tools or fixtures. Just a simple six foot work bench and standard hobby tools.

Sincerely;

Jerry Nelson
President, Nelson Hobby Specialties



      SPECIFICATIONS AND MORE INFORMATION

ITEMS OFFERED FOR PURCHASE
: Two versions of the plans are offered, the complete set and the standard set. Individual drawings will be made available with cost depending on the size of the drawings.

The Complete Set of plans: Price approximately $200.
The complete set of plans will have drawings for every part, assembly drawings, jig/fixture drawings. Included with the complete set of plans will be the complete instruction manual that also includes information on the making of the various jigs and fixtures.

The Standard Set of Plans: Price approximately $125 and will refundable with purchase of kit at a later date. The standard set of plans will be all the drawings necessary to build the model from the kit. The standard construction manual is included.

Example of drawings not included will be the individual drawings for the rudder spar components. The 5/16” diameter aluminum rudder spar has several parts. The steel rudder control horn is silver soldered to a 3/16” diameter 4130 steel tube that is inserted into the long top and the short bottom spar. This assembly is held in place with 1/16”x 5/16” long roll pins. In addition, there are several machined holes and slots for the hinges. This is not a complex assembly, but does require some tooling for it to fit properly into the assembly jig for the rudder. Since the rudder spar assembly is supplied in the kit in its final form, there is no reason to have individual drawings for the eight parts that make up the rudder spar assembly. Only the complete rudder spar assembly drawing is necessary and is the one supplied.

Another example of drawings not included will be the rib patterns in the tail group. The ribs will be supplied preformed with the kit and as all parts the individual parts are numbered with their individual part numbers. The ribs are formed from .016” 6061T-6 aluminum. They are bent to shape in a male/female metal tooling fixture. The standard drawings do not include the drawings for the tooling fixtures and the blank material to make the rib.

Complete Kit: Price is not certain yet but will be approximately $2,000. There will be only one basic kit offered, however there will be options for what kind of engine and what brand of servos will be used. Everything is included (other than tools) except the engine, silencer, and radio equipment. Even the fabric and paint are supplied. Some hardware store type of materials needs to be purchased such as particle board, drills, glues, sandpapers, and perhaps some tools that the modeler doesn’t have.

Selected JR or Futaba servos require different servo mounts and some changes in the control system design. This allows for the control system linkage to be supplied in a completed form. There will be a steel tubing motor mount provided for a limited selection of engines that are recommended. What engines are recommended is not available at this time. Initially the OS and Saito 300 4-cycle twins, the DA50, and the OS 4-cycle four cylinder engines will be suitable for use with the initial kit releases. The main engine requirement will be one that there is the ability to completely enclose the engine and there is a commerically available silencer that fits inside the cowl.

Individual component kits are available. There will be three individual partial kits available. This will spread out the cost of the total project thus allowing the kit to be more affordable for some modelers. The wing/wing strut, stabilizer/elevator/ rudder, and fuselage/landing gear/cowl will be offered as individual kits. The appropriate drawings and instructions will be provided. Total cost of the three partial kits will be more than if the complete kit is purchased.

The kit is so designed that the various major components are interchangeable.

Major Components Assembled.
Price not certain, but will be in excess of $3,000. The final price will be a direct function of the labor cost for us to assemble the major components. This version of the kit will feature prebuilt major components completed as they come out of their assembly jigs. They will not be ready to cover but not a lot of work is required to get them ready in their final form. What has to be finished for the fuselage will be the installation of the control system, installing the plywood fuselage bulkhead and the spruce stringers, installation of the gas tank and throttle linkage, fitting of the molded canopy, fitting of the cowl assembly, and other odds and ends.

It will be possible to actually bolt the tail group, the wing panels, struts, and landing gear to the fuselage as it is delivered to the customer. There is still a lot of work to be done, but the critical assembly work is finished thus providing a very accurate and true aircraft structure.

This version of the kit will not be released until the complete kits are in production.

Spare Parts:
All of the parts are accurately manufactured from jigs and fixtures and will be interchangeable for replacement units. All parts will have a part number and every part will be offered for sale.

Purchasing process: Deposits will not be taken until the prototype aircraft has been flown and tested and found to be satisfactory aerodynamically, structurally, and all systems are working properly.

We will be complying a list of individuals that have shown serious interest in the kit. After the prototype is proven satisfactory, those individuals will be contacted all at one time via a letter asking if they would like to purchase one of our Aeronca 7AC kits. A $500 deposit will be required to initiate a firm order. The $500 deposit is fully refundable by us within a 30 day time period. The order of when the deposits are received will determine the delivery position of future kits.

When the kit is ready for shipment, the customer will be notified and the balance of the payment will be requested. Unless otherwise indicated, the kit will held for 15 days waiting for the payment to be received. When the payment is received and processed, then the kit will be sent. If the payment is not received within the specified time period, then the delivery position will be moved to the next customer. The deposit will be held pending final payment and then put onto the next available kit.

Those customers from the initial list will have a firm price established for the kit. As we get into the production of the kits, there can be a price increase due to the cost of material increases, reengineering costs, labor costs changes, and other unexpected costs of producing the kit. Anyone sending in the $500 deposit will have fixed retail price for that order.

The kits are only available from our manufacturing facility. The kits will not be sold to dealers.


SPECIAL FEATURES

Drawings: The computer drawings are done in AutoCAD®. The complete set of drawings consists of over 100 drawings. Most drawings are full size. Every part has a drawing and a part number. Assembly drawings show, in detail, where all the parts are located. Where appropriate, there are drawings provided for the construction of the building and alignment jigs, and drawings that are to be used as cut out paper templates and also assembly drawings that are intended to be contact cemented to 3/4” particle board.

Instructions: Extremely detailed instructions are provided that include over 50 digital photographs. Included in the instructions is what type of tools and equipment is recommended to perform the task at hand. References are offered to why a certain process has to be done in a certain way so that errors will not occur. Reference marks are provided for so that during the construction process the builder checks off the various steps as they are finished. Digital photographs are a key part of the instructions.

Special tools required: A small band saw, a drill press that will take up to ¼” diameter drills, and a belt sander are required to build the model from only our plans. A band saw is helpful to build from the kit since some of the tubing needs to be cut and the wing spars cut to length. The aluminum tubing does cut easily with a hacksaw, but a $175 band saw from Sears makes life a lot easier. There are several $100 drill presses available from many sources.

Jigs & Fixtures: Included in the complete set of drawings are drawings and instructions on the fabrication of jigs and fixtures to drill and cut parts, and for the assembly of the components. The materials for the assembly jigs are made from 3/4“particle board. Paper cut out drawings are provided so the printed assembly drawings can be contact cemented to the particle board. In this manner the original drawings are not destroyed by cutting.


Epoxy used to join aluminum parts:
MetalWeld™, a two-part epoxy is used to join the various parts of aluminum and steel. This epoxy provides a joint that is as strong as the aluminum tubing. A tubing joint that is forcibly bent will fail at the edge of the gusset and not at the joint itself. This epoxy has a working time of 2 hours and cures in 10 hours and less if heated. With simple heating processes, cure time can be under 4 hours.


Fuselage: Fuselage construction is the same as the full-scale aircraft. The Aeronca 7AC series aircraft features a unique triangular aft section of the fuselage. Laser cut plywood bulkheads are attached to the structure and spruce stringers are installed to form the somewhat rectangular shape.

The fuselage is made out of mostly 3/16” and 1/4” diameter 6061T-6 aluminum aircraft quality tubing that is joined together with the MetalWeld™ epoxy. Brackets, fittings, and gussets are made from 2024T-3 or 7075T-6 aluminum sheet from .016" to 1/16” thick. In addition, there are some 4130 steel fittings. Fuselage is made from preassembled tubing bulkheads and assembled on a simple particle board jig. Fixtures accurately align the stabilizer, vertical fin, wing spar fittings, and the motor mount.

Special 4130 steel tubing motors mounts are provided for several different engines. The motor mount is attached to the firewall with neoprene shock absorbing inserts. The selection of recommended engines will be determined by what type of silencer system that will fit into the dimensions of the cowl. Every effort will be made to insure that the engine/silencer will be completely hidden inside the cowl’s contours.

Molded canopy is supplied thus duplicating the unique shape of the Champion windshield. The cockpit door opens providing access to the receiver and batteries located in the baggage compartment behind the rear seat.


Control System: The rudder is operated with a scale pull-pull control system. The elevators are operated with aluminum tubing pushrods.The ailerons are operated by a pushrod and ball bearing bellcranks with individual heavy duty 135 in/oz servos located at the root of each wing. Rudder and two elevator 135 in/oz servos are located at the mid section of the fuselage. Two individual pull-pull elevator systems are used to provide additional redundancy. The throttle servo, break servo, receiver, and batteries are located on or under the floor, seats, and in the baggage compartment area behind the rear seat.

Our own heavy duty aluminum servo arms and ball bearing bellcranks are provided in the kit. The necessary servo arms are available for the JR and Futaba standard size 100-140 inch ounce servos. An aluminum JR or Futaba servo tray is supplied for the rudder and elevator servos. At this time, not certain on what kind or if any, servo trays will be used for the aileron, throttle and brake servos.


Tail Group: Tail group is completely made from aluminum expect for the steel control arm assemblies. The ribs will be supplied preformed, however minor trimming at the trailing edge of the rib is required. The leading edge of the stabilizer and the top portion of the rudder are tubing and will be supplied bent to shape. The rudder spar, elevator and stabilizer spar assemblies are supplied finished. The hinges are made from short lengths of aircraft piano hinges and firmly held in place with 1/16" roll pins.  They are very scale in appearance to the welded to the frames three part steel tubing hinges as used in the full-scale aircraft. The trailing edge of the rudder is from 1/8” diameter tubing and is easily bent by the modeler. The 3/16” diameter trailing edges of the elevators are supplied preshaped.

Wing: Wing consists of individual right and left-hand panels. The spars are made from ¼” square spruce and are easily assembled by the builder. This is done for ease of shipping. A two-part drill jig will be provided to accurately drill the various holes in the spar after it is white glued together. The splice bevels are supplied precut. The wing spars are reinforced with compression tubes and diagonal piano wire braces with adjustable clevises. This type of reinforcing is very close to scale for this type of wing structure. Wing tips are pre-bent 3/16” aluminum tubing.

The ribs in the full-scale aircraft are made from aluminum sheet. We could do this, but the cost to do so is very expensive and just not practical. Our ribs are made from 1/8” LitePly. Not scale but the ribs have the same lighting holes and are very realistic. The actual scale flange with of the full-size ribs in our 30% scale are .115” thick. Our LitePly ribs are .113” thick. Almost the same. For show and tell purposes, we suggest that the ribs be painted with hardware store spray can silver. At least one side of the rib will be scale. Trailing edge of the wing is made from fiberglass epoxy G-10 material. This provides for a very strong trailing edge with its narrow width. The leading edge of the aircraft is sheeted also with the G-10 material.

Wing spar fittings are made from 7075T-6 aluminum 1/16” thick. These are supplied precut and drilled.

The ailerons are made from spruce, LitePly and G-10 material. The hinges are scale and consist of aluminum brackets attached to the trailing edge of the wing and protruding aft with nylon bushings at the three hinge points. There are two aluminum bellcranks with ball bearings used in the aileron control system. 3/16” diameter aluminum pushrods are used to operate the system. The aileron servo is accessible from the rib cutout holes at the root rib.

Wing Struts: Wing struts are from ¼” and 5/16” diameter 6061T-6 aluminum tubing. Attach fittings are made from 1/16” 2024T-3 aluminum sheet and are attached to the aluminum tubing struts. MetalWeld epoxy is also used for the attachment as well as providing additional contours to replicate the full-scale strut fittings. ¾” and ½” streamline Modified K&S tubing is placed over the aluminum tubing only for appearance. The K&S tubing is not strong enough for this application.

Covering and Paint: The aircraft is covered with our NELSON LiteFAB and is supplied with the kit. NELSON Hobby water reducible paint is also supplied in the traditional yellow and orange trim colors. The Aeronca logo for the vertical fin is also supplied. Black “N” numbers for the wing and vertical fin are included and will be made available on a custom basis. Thin plastic items are provided to duplicate the inspection holes and drain grommets. Scale pinking tape made from our NELSON LiteFAB is provided. The full-scale 7AC Champion does not use rib stitching, instead uses #4 sheet metal screws to hold the fabric to the ribs. We will use #0 sheet metal screws instead. Quite close to scale.

Landing gear and tail wheel assembly:
The scale landing gear features a simulated oleo strut shock absorbing system. This is a very desirable design both for the full scale aircraft and our model. The landing gear is fabricated from 4130 steel tubing with an internal coil spring from the shock absorbing system.

Initially the model kit will be provided standard 5” diameter wheels. Soon as the kit is in production an optional special tire will be made that is an exact scale version of the full-scale aircraft tire. A scale CNC machined aluminum wheel will also be manufactured that will feature built in mechanical breaks.

A scale Scott Type tail wheel sold by Sirrus Ventures is included in the kit. Sirrus sells the unit for $95.00.

Fiberglass wheel pants will be available as an optional purchase. Most of the full-scale aircraft did not use wheel pants.

Cowl: The cowl will be fabricated from .016 6061T-6-aluminum sheet as done with the full-scale Aeronca 7AC. Miniature piano hinges on the top of the cowl are already in place and will allow the opening of either side of the cowl to allow access to the engine for adjustment and or starting purposes. The front portion (nose bowl) of the cowl is made from fiberglass. Perhaps it can be formed from aluminum, but certain at this time.

Cockpit detail:
Supplied is the material to make scale-like seats made from brass tubing and joined with StayBrite™ silver solder will make realistic seats. Raw material to make leather like seat covers add more realism.

Material is supplied to make scale like rudder pedals, control sticks, elevator trim tab lever, and throttle controls are simulated to a high degree of realism.

Printed colored instruments and instrument panel are provided to make a realistic full-scale instrument panel.

Part identification: In general terms, if the complete kit were purchased, the customer will be receiving four boxes. One box of parts for the tail group, another for the fuselage, one for the wing, and another for the cowl, landing rear, mount, and control linkages.

Within those boxes there will be additional boxes and plastic zip lock bags with parts. All of the boxes and bags will have a list of materials what will be checked off by the customer to insure there are no missing parts and also for the builder be aware of of what parts are supplied.

When possible, all parts will be individually labeled A bag of screws will be labeled, but the individual screws will not. The labeling system is designed so that the customer can find out how to find the appropriate drawing describing the part and were it is used.

SPECIFICATIONS AND PRICES ARE SUBJECT TO CHANGE WITHOUT NOTICE.