Wednesday, June 22, 2016

EMG-6 "Shop Notes" June 2016

"EMG-6 Shop Notes" is a day-to-day accounting of what's going on in the shop with the EMG-6 Electric Motor Glider.

June 22, 2016   R&D Motor Installation Begins

We have begun the installation process of the R&D motor. remember the design criteria that we have the motors be able to be plug-and-play. The standard installation method simply involves installing the motor subassembly into the airframe and securing it with one bolt.

Thursday, June 16, 2016

Ultraflight Batteries

 "Donald Lineback" Batteries

June 17, 2016

More information from Donald Lineback on his battery systems he has been developing.
Donald's latest email

"We can test 14 cells or 22 cells in one pack or add another to make a 36 cell with 150v. We can test DC or the better choice - AC sinusoidal.
We supply various controllers and provide programing and wiring for BMS or PCM protection. We offer various throttles and fuel gauges. 
Our new motor and variable pitch prop will be available soon. The battery pack sizes range from 30Ah to 180Ah in cylindrical and pouch. 
— Stay in touch to see our hybrid system for cross country electric flight. ---"

Sunday, June 12, 2016

"Video" EMG-6-250 Local Flights

Carol Carpenter Flies the EMG-6-250. These are the last flights on the EMG-6-250 . The engine and many of the parts were removed to complete Prototype #2 in order to start the Installation of the Polini 250 into the Cabin of Prototype #3. This will be a completely enclosed version similar to Prototype #2 but #2 is currently being fitted with the Electric Power Plant.

Saturday, June 11, 2016

"Video" Cutting Flight Control Gap Seals from Pool Noodles

Cutting Flight Control Gap Seals from Pool Noodles

In this video we go through the process of converting pool noodles into low-cost lightweight, and easy to install  foam gap seals for the EMG-6 electric motor glider.

Let's go through the detailed procedures on how we came up with the final results that we have been using on the EMG-6 electric motor glider. We have cut nearly 30 different dies and guide blocks to come up with the final results that we found that work very well.

Thursday, June 9, 2016

R&D Motor

R&D Motor

 This page is dedicated to  any updates and information regarding the R&D Motor.

 June 9, 2016   Motor Update


 Today we had a meeting with Ed Donovan owner of R&D cable. Ed and his team are developing an electric motor that will be used on the EMG-6 electric motor glider. The design parameters are basically to design a 20 hp continuous operating motor turning at 2500 RPM and producing approximately 65 foot-pounds of torque. We will be spinning a 48 inch diameter propeller. this motor is simply a dummy motor that does not have the winding's and magnets inside but was delivered so that we can use it for the development of the motor mounting system on the EMG 6 as both as a pusher and as a tractor on the to the wing pylon locations. The bolt pattern is the standard two-stroke Rotax engine bolt pattern. the bearing is the same as the front bearing on the Rotax E gearbox. The total motor weight will be in the neighborhood of 25 pounds when completed. There are 6 mounting locations on the rear of the motor housing. During testing at full power  the outer housing gets slightly warm but the winding's and the magnets remain cool even at full power operation. They are still undergoing some operational tests on the motor and perfecting the final design before going into the  mass production phase and developing the tooling for the stamping dies for the winding core. The expectations are that the efficiency of the motor will exceed 95%.. And reliability and durability are  key components in the development of the motor. I would expect that this motor will have a TBO in excess of 10,000 hours. And overhaul cost will be the replacement of 2 bearings. We have been told that we should expect to have a operational motor available for installation before we depart for the Oshkosh airshow.

Tuesday, June 7, 2016

Low-Budget Hydro-forming Sport Aviation / Experimenter "Technically Speaking" Article May 2016

Low-Budget Hydro-forming

We are often looking for methods for creating parts on our experimental aircraft that replicate the professionalism of factory built aircraft. The biggest stumbling block is usually the cost of set up for fancy tooling and machinery. Yet, you might be surprised by what you can accomplish in your own small workshop. In fact, many of the greatest ideas in aviation originated from small workshops like yours.

Saturday, May 21, 2016

EMG-6 "Shop Notes" May 2016

"EMG-6 Shop Notes" is a day-to-day accounting of what's going on in the shop with the EMG-6 Electric Motor Glider.

May 31, 2016  Prototype #2 Nears Completion

As the month of May comes to a close where getting very close to finishing up all of the small details on the aircraft. We are still awaiting the FAA registration so that we can certificate the aircraft and begin flight testing.

Tuesday, May 10, 2016

Monday, May 2, 2016

"Spark Plugs and The Rotax Engine: Part 3" Sport Aviation / Experimenter "Technically Speaking" Article April 2016

Spark plugs and the Rotax Engine Part 3

In part 1, we discussed the theoretical aspects of the spark plugs. In part 2, we talked about the more practical aspects of installation and maintenance of the spark plugs installed in the Rotax engine. In this, part 3, we are going to take a look at using the spark plug as a troubleshooting tool.

The engine will continuously communicate her condition to you through a multitude of sources. One of the most powerful sources of information about an engine’s internal condition comes from what the spark plugs have to tell you. We call this “reading” the spark plug. (Figure: 1) One advantage of reading the spark plugs is that they don’t often lie. Engine instrumentation can give us a lot of clues about what’s going on inside the combustion chamber, but they are limited, both in the scope and in their accuracy. We see aircraft owners pulling their hair out, modifying the engine, trying to make it operate in a configuration so that the instruments read “normal”, only to find out months later that their instrumentation has been indicating incorrectly all along. By this time, they have modified the engine so far from the stock configuration that the road back to proper operation if often frustrating and expensive.
When we talk about reading the spark plug, we are primarily talking about reading the color of the ceramic insulator that surrounds the center electrode. The automotive industry, and in particular the racing industry, has carried this reading of the spark plugs  to a very fine, nuanced science. And although engine to engine readings vary substantially, we can take away from some general principles that you should be able to apply to your particular engine. It is common that we can get information about all segments of the engine operation from idle to full throttle by looking at selected segments of the spark plug.  Idle operation  can be revealed by looking at the face  of the threaded spark plug body. Midrange, the place where you spend most of your operating time on the engine, shows itself primarily towards the end of the ceramic insulator where the center electrode protrudes. And full throttle operation is more indicative of a ceramic insulator deep inside the area where the ceramic makes contact with the spark plug body. Now I caution you, these principles need to be associated with  a significant understanding of the operating characteristics of your particular engine. Even the visual appearance of a Rotax 582 two-stroke engine versus a Rotax  912 four-stroke engine under normal operating conditions  will have a substantially different appearance.

Friday, April 22, 2016

EMG-6 "Shop Notes" April 2016

"EMG-6 Shop Notes" is a day-to-day accounting of what's going on in the shop with the EMG-6 Electric Motor Glider.

April 22, 2016 Progress Update

This last week we have accomplished quite a bit of detail work on the aircraft. One of the areas that we've been working on is the 3-D printed fairings. We have now finished and installed temporarily the forward wing strut fairings.

The fairing with primer and initial sanding undergoing a test fit before we continue on with the rest of the finish work.

Thursday, March 31, 2016

"Spark Plugs and The Rotax Engine: Part 2" Sport Aviation / Experimenter "Technically Speaking" Article March 2016

Spark plugs and the Rotax Engine Part 2

In part 1 of this article, we discussed the theoretical aspects of the spark plugs installed in the Rotax engines. In this article, we will take a more in-depth look at the practical aspects and the “how to” of the spark plug in the Rotax engine.

Spark Plug Removal. When removing the spark plugs, during an annual inspection or any time for that matter, keep in mind that there is a lot of information to be had by “reading the spark plugs.” A spark plug rack is a useful way to keep track of the cylinder position of the spark plugs as you remove them. The spark plug rack should be labeled with both the cylinder number as well as top or bottom position. (Figure 1)

Wednesday, March 30, 2016

53-50 Wings to Fuselage Fairing

Builder Guide

53 Fuselage

53-50 Wing to Fuselage Fairing

This is a one-off prototype wing to fuselage fairing that were making. We will update this once we get to the production aircraft.  This will be the premise for the design for the production fairing that utilizes the BRS ballistic parachute system.

Before we begin the prototyping process for this fairing it's important that you have a visual picture in your head of what it's going to look like.

With that in mind we get started with building the center box that we will use to build the fairing from.  Were making this box from 1/4 inch plywood  and the skins from 1/8 inch mahogany door skin.  Both of these pieces of plywood are relatively cheap $12-$15 for a 4 x 8 sheet.

We create bulkheads for the sides of the center box that will carry the profile from the fuselage boom up over the ballistic parachute and transition down to the forward keel. We will need the transition to occur slightly above the keel so that we can use the keel overhead to assist in climbing in and out of the aircraft. 

Wednesday, March 23, 2016

EMG-6 "Shop Notes" March 2016

"EMG-6 Shop Notes" is a day-to-day accounting of what's going on in the shop with the EMG-6 Electric Motor Glider.

March 29, 2016 Flight Controls

In this picture here we are wet sanding and prepping the ailerons and horizontal stabilizers for the next coat of poly spray silver.

Monday, March 21, 2016

3D Printed Parts

This page will be dedicated to the 3-D printing process for components used on the EMG-6.

Trailing Edge Lift Strut Eye Bolt Fairing

The trailing edge lift strut eye bolt also has a large protrusion with the nut and washer sticking up above the rear spar. This is our fairing that fits over that nut to reduce the drag in this area. This is prototype #1 and was a pretty close fit from the get-go but needed a few modifications.

Monday, March 14, 2016

01-50 Tube Marking (Video)

Another episode of "Building the EMG-6".  In this episode we look at the process of marking tubing. Pretty much every component on the EMG 6 uses tubing for construction. In this video we show you how to accurately and easily mark tubing for these applications.

55-21-20 Horizontal Stab Leading Edge, How it's Made (Video)

Friday, March 11, 2016

55-21-34 Inboard Rib Building the EMG-6 (Video)

This is a 26 minute long video with step-by-step instructions on installing the horizontal stabilizer rib assemblies. This video also contains some good information on how to mark tubing.

Tuesday, March 1, 2016

01-50 Tube Marking Guides

Builders Guide

01-50 Tube Marking Guides

Link to Builders Data Base (Tube Marking Guides)

In order to be able to use the tube marking template on the right side of each of the drawings you need to download the PDF file from the builders database and print them out on your home computer at 100% scale. Before using the template  you should check its physical dimensions with a pair of calipers.

55-21 Horizontal Stabilizer (LD)

Builders Guide

55 Stabilizers

55-21 Horizontal Stabilizer (LD)

Horizontal Stabilizer Main Spar Sub-assembly

We will start the construction of the horizontal stabilizer assembly by beginning with the main spar sub-assemblies. This consists of the main spar to with reinforcing sleeves inserted in 3 locations.

The first part that we have to create is the horizontal stabilizer spar tube.  We will be creating all of the reference marks on the main spar tube. We will start with generating a reference line down the length of the spar.

55 Stabilizers

Builders Guide

55 Stabilizers

55-10 Vertical Stabilizer Assembly

55-20 Horizontal Stabilizer Assembly

Monday, February 29, 2016

EMG-6 "Shop Notes" February 2016

"EMG-6 Shop Notes" is a day-to-day accounting of what's going on in the shop with the EMG-6 Electric Motor Glider.

February 29, 2016

"Spark Plugs and The Rotax Engine: Part 1" Sport Aviation / Experimenter "Technically Speaking" Article February 2016


February 26, 2016

More files added to the builders database for the main landing gear assembly.

"Spark Plugs and The Rotax Engine: Part 1" Sport Aviation / Experimenter "Technically Speaking" Article February 2016

Spark Plugs and The Rotax Engine:  Part 1

We continue to see problems surrounding the use of spark plugs in Rotax engines. Many of the rules which we have used in the past for typical aviation type spark plugs, used on air cooled engines, no longer apply to the automotive type spark plugs used in a Rotax engine. As with most technical subjects, an underlying understanding of the theory and physics involved is essential to our ability to make good judgments about the use and operation of spark plugs. So let’s start with the basics.

The spark plugs used in the Rotax engines are specific to each type of engine. Figure: 1. The most prolific of the Rotax engines is the 912S 100 hp and it uses the DCPR8E. Figure: 2. Using this plug let’s look at the part number designation and what each one of the numbers and letters indicate for the design of the spark plug.


Spark Plug Size: The (DC) in the part number is the thread diameter and pitch. Looking at the NGK part numbering chart, it indicates that this is a 12 mm diameter spark plug with a 1.25 mm pitch on the threads and uses a 16mm wrench on the hex portion of the spark plug.
Reach: The Last Letter in the part number (E) indicates that this plug has a 19 mm thread reach. This is measured from the base of the plug, above the gasket, to the last thread.
Shape: The (P) in the part number indicates this plug has a projected center electrode insulator. The projected center electrode insulator is what you would normally recognize as a typical spark plug and is of course the most common type.
Construction: And the (R) in the part number indicates this is a resistor type spark plug. When a spark jumps the gap on a spark plug, it creates a high frequency burst of energy. This creates radio frequency interference or (RFI) which can generate significant interference with your radios and other electronic equipment. Placing a resistor within the spark plug significantly reduces this RFI. Figure: 3.

Heat Range: The (8) in the part number is an indicator of the heat range. The heat range of the spark plug is designated by the ability of the spark plug to dissipate heat that is absorbed from the combustion chamber. The heat within the insulator nose is transferred into the body of the spark plug and out into the cylinder head which is cooled by air or by water/antifreeze.

Saturday, February 27, 2016

Carol's Transition Training in the EMG-6-250

In this totally unscripted video we see the start to finish process of Carol making the transition to her first flight in the EMG-6.

Wednesday, February 24, 2016

Carol Carpenter Fly's the EMG-6

By Carol Carpenter

The thing about life with Brian is that everything happens "suddenly." There was no discussion leading up to Brian setting up the EMG for me to fly this evening . . .so I did not have time anticipated the event. He just asked me to sit in the plane and started adjusting the seat. The next thing I know, I am in the pilot seat and, to be honest, somewhat apprehensive.
I am buckled in, with a helmet on, and thinking. . . I don't know about this.

Sunday, February 21, 2016

25-30-33 Pilots Seat Back

Builders Guide

25-30 Ergonomics

25-30-33 Pilots Seat Back

These pictures that we are covering here show some of the old design pilot seat latching mechanism. We will modify that design

25-30 Ergonomics

Builders Guide

25 Equipment and Furnishings

25-30 Ergonomics

Link To Builders Data Base


25-30 Seating Assembly

25-30-01 Pilots Seat Assembly

25-30-33 Pilots Seat Back Standard

25-30-34 Pilots Seat Back Hinge

25-30-50 Pilots Seat Belt

25-30-51 Passenger Seat Belts

Saturday, February 20, 2016

55-22 Horizontal Stabilizer Trim (video)

"Designing the EMG-6" (Video)

In this video we look at the design of the electric stabilizer trim system for the EMG-6 electric motor glider.

Tuesday, February 16, 2016

Re: Is the EMG-6 capable of meeting the Part 103 using the Ploini Thor 250 engine?

On Thu, Feb 11, 2016 at 12:31 PM, steve wrote:
You have received a contact request from a visitor to your storefront at

E-mail Address: ***********
Name: Stephen **********
Company: ************
Phone Number: *************

Is the EMG-6 capable of meeting the Part 103 Ultralite requirements using the Ploini Thor 250 engine?

Does the pricing of the kits, IE Rudder Kit, Fuselage kit, include shipping?  What would be shipping to 65810?

Does the cost of the Platinum series include all parts and shipping?

What parts must the builder supply and the average build time?  I know, you have been working on this design for several years, and are still building!  Good for you!  But what about the average person?

What would a complete kit cost, picked up in Corning , CA. without a motor.  I need a vacation!!


Thank you,
The Quick Shopping Cart Team

72-40 SINETON A37K154 Electric Motor

Builders Guide

72 Motors

72-40 SINETON A37K154 Electric Motor

Potential Motor for the EMG-6

A lightweight coaxial air flow cooled permanent magnet synchronous motor designed to directly drive a propeller. Optimized for high continuous torque density and efficiency. With 17 kg of weight (option dependent) it's capable of supplying up to 30 kW of continuous power at 2000 min-1 providing higher than 93% efficiency. The speed-torque diagram of the A37K154 with a three phase 14Y2 winding configuration is displayed on the bottom figure. The curves are stipulated for different DC bus voltages, without any field weakening applied.

Link to Builders Data Base and  full PDF