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