Well everyone is building a plane so why not me. I had built a Hawker Hurricane last November but still not flown as my receivers are still to be unpacked. (My aeromodelling stuff was lying packed in my old house in Lucknow for last 6 years because of my frequent transfers. Now retired). With the sweepstakes on , I thought why not build one more biofoam electric. While I used to fly glow powered planes earlier, I am absolutely new to electrics. I have started building a World War I model - a Fokker DR VII biplane.

The build uses a laminated construction technique where the fuselage is built of seven pieces of 6mm biofoam. Cutouts have been made for the battery, esc and receiver.

I hope that the build gets completed by 15th. So here are the build photographs

The plans were traced on a biofoam sheet

.

And then cut

Next step was to laminate the fuselage parts, beginning with the innermost two layers. The fuselage was reinforced with a Carbon fibre strip (seen at the lower end)

And then gluing the remaining layers to form the fuselage. The front part has 7 layers. The right hand side has openings for the ESC and servos while the left hand side has opening for the servos and receiver. Channels have been made for passing the wires

The tail section has 3 layers with appropriate cuts for the tail feathers

All the best sir !!! 
And clean cut i love them 

Regards
yash

Next step will be to sand the fuselage and build the wings. Updates will follow....

Quote from my post of 24th March in Indore Bipe thread:

"This Mr Ashok Baijal has come out of hiding.
He started aeromodelling in 1982.
Now retired and has all the time in the world.
So watch out for him.
Please welcome Mr Baijal to RC India"

Now we know why he is searching for a compressor for his airbrush!

Indeed Iyer Sir!!

Really fascinating build Mr. Baijal sir!

All the best sir. 
Very neat work...

 

I started into aeromodelling when I was in class V in early 60s. My first build was a balsa glider which was gifted to me by my taiji (aunt). The price of the kit was less than Rs 10.a neat sum during those days.Next was a large glider I had purchased from hobby centre in 1970. The kit was around Rs35  at that time. It crashed on its maiden as I forgot/ was unaware of ading a nose weight. When we met in 1982 it was my first powered model. The diesel engine costed Rs250 about 20% of the montly salary we used to get as officers in a bank. Many stories in between which we can share separately.

Sir where did you lived in Lucknow?
Things were so cheap in those days, although, it was a big amount in those times.
 

Thanks for the encouragement.

I explored various options for cutting. First and cleanest is access to a laser cutter cnc machine which was not a viable option. Next was to build a hot wire cutter. My power.supply for my nicd charger had a fuse rated at 2.5 amp which promptly blew up on attaching the nichrome wire. And no spares so this option was  closed till I go to the market maybe once the weather cools down. So back to a cutting blade.
The trick for a clean edge is to have sharp blades. I use 11 no surgical blades which I buy in bulk. I used 3 blades for cutting this model. The second trick is to cut oversize and leave an edge of around one mm. The next step is to sand the edges for a perfect shape. In short cut a d sand edges flush..

I used to live in India Nagar. Since I have only one son who is currently in Bangalore I sold off the Lucknow house and shifted to Bangalore. Still I have lots of things to attend to so I will be back in the north in mid june and be back by year end. So aeromodelling will really restart next year.

sir i was in indira nagar till 2004 now live at sahara states,jankipuram area will definately try to meet you when you will be in lucknow sir

Regards
yash

I too live at Indira Nagar Sir. Very happy to see people from our city joining back again.

So the build continues. Today morning I checked up whether the fevicol had dried, which it had. So before the morning cup of tea I sanded the edges and had a nicely shaped fuselage

Next was a check that the tail feathers would align properly in the slots. So a dry fit and they fit in snugly.

Then it was time to check if the slots for the wing were also properly sized. And yes the wing fits in and is perfectly horizontal

So time to start work on the wings. Everything snaps into place till now

The wings have a KFm panel which sits on the lower side. The KFm panel were cut in two pieces though one would have been better. The wings are strengthened with a carbon fibre rod. Also two pieces of balsa wood are arranged at the spots where the struts would come. A slot is cut for the carbon fibre just near the edge of the KFm panel and then the wing is left to dry after applying a coat of Fevicol

The upper wing, however, has a dihedral of around 10 degrees. As such the wing panel has to be bent. For doing so, I scored a line in the middle using a flat metal scribe and reinforced the back side with tape before bending it

Next came the issue of bending the carbon Fibre rod which is not possible. So I prepared a small jig which is nothing but a scrap piece of wood and I attached a few nails to act as a guide for placing two pieces of Carbon Fibre rod. I inserted a small piece of wire to stiffen the centre at the required angle. Added araldite and tied a piece of fibre glass thread to the joint and I have left it to dry overnight.

So while the reinforcement for the upper wing is drying, I shifted focus to the tail feathers. The elevator was cut off from the tail plane while the rudder was cut off from the vertical stabiliser. Next step was to hinge the control surfaces. Being from the old school I prefer hinges to using a tape. So two hinges each were attached to the two control surfaces using araldite and left to dry overnight

@ashok baijal
Didn't you note in my Indore Bipe build that the dihedral brace is a 3" piece of cycle spoke bent in the middle and inserted into the cf tube spars?
Great progress. Should get done by Saturday night.

Lesson in workmanship.
Just look at the edges of the tail parts!

The araldite on the hinges of the tail feathers had dried by morning. The first task done today was fixing them to the fuselage.

The KFm panels on the wings had also dried overnight. The leading edge was shaped to give the wing an aerofoil shape. The same was repeated for the upper wing also which had a 8-10 degree dihedral.

Araldite has 5 min epoxy now

I prepared control horns by cutting shaped pieces from a tongue depressor. The wooden tongue depressor is made of a thin but stiff wood and I found it good for the purpose. I strengthened the tips by applying a few drops of feviquick.

I also found the control rods required were a bit long and the wire I was planning to use had a bit of slop. So I prepared carbon fibre control rods by attaching the Z shaped ends to the carbon rod using feviquick and covering the joint with heat shrink tubing.

nice build 

@Iyer
Araldite also has "Araldite Rapid" which is quick drying. I prefer to use it at the flying field. Maybe now they have started calling it Araldite Klear. In my old age I use the normal Araldite as I can do my work a bit slowly   

Thanks guys for the encouragement 

@ashok baijal
Just noticed that a
DRVII DR VIII
is a monoplane parasol!

Some photos of Fokker DRVII taken from wikiipedia

By the way, just noticed that the heading of the thread says its a Fokker DRVIII build though I am building the DRVII as stated in the opening first post. Sorry guys for the mistake. Another one is that the thread is grouped under "RC EQUIPMENT" instead of  "ELECTRIC PLANES". Need help from Admin to correct  

Thanks. Since done.

Ashokji, keenly watching your Build. Beautiful all i can say, neat cuts.

K.K.Iyer sir, the Fokker E.V or the D VIII was the monoplane that you were referring to. It had the distinction of scoring the final aerial kill of the Great War.

Incidentally, Baijal Sahib, beautiful workmanship. Where were you, incognito, all these days?

@VC
Been practically out of the hobby for last 5-6 years because of frequent transfers. Finally retired in Jan 13 but fate was still not reconciled to allow me to settle down. Lots of family/health problems. Still do not see end of the tunnel.
Incidentally me and Iyer worked for the same organisation and in 92-93 shared the same room in office.

After fixing the control rods, it was turn for fixing the wings. The lower wing was the first one to be attached. A few boxes of nails were balanced on top of the fuselage to apply pressure while the glue set. Incidentally a view of my small workshop

Next I cut two pieces of foam to serve as an alignment jig for the upper wing as it is supported by struts only. I decided on using carbon Fibre rods for making the struts as I did not have the bamboo sticks. I pinned the alignment jig pieces to a cardboard box to keep them vertical during the period that the struts were glued.

This time I used Araldite Rapid, as suggested by Iyer.

Once the outer struts had set, I removed the support jig pieces and then attached the inner struts.

The rear skid was prepared by bending a cycle spoke

Since I did not have front wheels readymade, I decided to make one. I cut two round pies from 1/8" balsa and four more pieces of slightly larger dia of 1/16" balsa to serve as outer rims. Once the glue dried I attached a rubber tubing (used in the valve of bicycles) using fevibond. The axle hub was prepared using a small piece of brass tubing (from my glow engine set ups). The wheels quite match the wheels used in the real Fokker DR VIIs 

If only I can get the rubber patch which is used for repairing punctures I would have covered the joint where the two ends of the rubber tubing meet. Fivibond was not of much help there.

Excuse me Sir, don't mean to jump the gun, what paint pattern do you have in mind? I hope it is the 'lozenge' scheme......

Paint will have to wait as I have to buy a compressor for my airbrush. Waiting for weather to cool down a bit so that I can go hunting for one. I think we should cut out the "Sir" business. After all old men are kids again. See how we play with our grandchildren  Today evening, incidentally, we are celebrating my granddaughter's second birthday. I think the "sir" is stripped off the day you retire   

How did you cut those perfectly round disks?

If using fuel tube or valve tube for tyres, cut to size, then insert a 2-3mm piece of toothpick half way into each end, hold together and put a drop of CA. Before mounting on hub.

 Thanks Iyer. Will try with another set of wheels.

I did not have a compass so used a round object to trace the circle. (In fact, it was a small speaker you find in the electronic cards). The circle for the outer rims were drawn freehand using the speaker outline as a reference. I found the centre by cutting a paper disc and folding it twice. The intersection point was the centre  . Then it was sandpaper and a bit of elbow grease.

Very nice sir. Especially the self made wheels.

The landing gear is in place. Now for the electronics. probably tomorrow.

Ashok sir,

What do you use for laminating the foam, any tips and tricks could be useful.
i use color paper(oil paper) for covering but it shrinks a lot and spoils the look.

Ashok.P

I have not used paper for liminating in this model. The fuselage is built by laminating 7 pieces of bio-foam

However, I have built a few glow powered 46 size planes using 7mm bio-foam. In such models the foam used for building the models is laminated on the inside with brown paper while the outer side is covered with vinyl which is used for preparing signs and sticks on one side. I have flown these planes for a few years and are still in good shape. I am attaching a few photos of the planes built using this method. The models are P51, and two Cessana with 25 size engines.

I recall reading an article in aero modeller published long back where the author who was the pioneer in the use of foam for rc models covered his models with strips of newspaper, and after the glue had dried sanded the edges smooth. A coat of paint was all that was required thereafter. Try strips of brown paper/newspaper and a coat of paint. You will have a very sturdy model. After all paper is cellulose which is a derivative of wood. I have preserved that article but after my frequent shifting lot of my stuff is lost/left/untraceable. Maybe Iyer or other old timers might have the article in their collection and would like to share.

Ashok Sir those are beautiful Creations . 

A chopper head below the Mustang?

@Sundaram
Thanks for your compliments. In fact I owe my gratitude to my dear friend Mr Darius Engineer who introduced me to this method of construction.

@Iyer
You have seen the cramped confines of my workshop so models have to live in multi-storied cubicles like his owner. P51 occupies the upper floor while the raptor lives on the lower one.

The landing gear looks awesome, the shape in which you have bent the cycle spokes has left me wondering how you did it .

Here are the pictures. Total 3 spokes used for making the landing gear.

Truly wonderful builds! Salute you  maestro

Iyer sir: you can use hole saw for a perfect round cut. hole saw for drill machines are easily available in the local market it will cost you around Rs.250-500.

http://rover.ebay.in/rover/1/4686-187859-10941-98/2?&mpre=http://www.ebay.in/itm/16pc-hole-saw-set-/171218437493?pt=lh_defaultdomain_203&site=Partnership_PLA&fvf=6

The original Fokker DR7 had an airfoil attached to the wheel axle. So I built one

Guys help needed. . I just took out the LiPo I was planning to use. They have a JST connector. I urgently need a few JST connectors for attaching the ESC to the battery. RCDhamaka and rCBazaar are out of stock. Any one having spare JST female connectors. I need to do the maiden before 15th

The total weight is coming to 354 gms. I plan to use
Blue Wonder (Though the version I got from hobby king is crome coloured) 1700 kv motor
12A Hobbyking ESC
8x4 prop
Turnigy nanotech 850mah 2S 25c lipo
Cirrus 6ch mini receiver 72mhz

The wingspan is 33in, length 24in, area 300sq in.

Just checked. A JST connector is rated at max 5 amp. So will be changing the battery connectors to Deans as the motor will draw around 10 amps

Ashok sir check this out
 http://www.kinetichobbies.com/index.php/female-jst-connector-with-20awg-silicone-wire-l-10cm.html

excellent build sir best of luck for maiden 

Sir Best of luck for the maiden. 

Will there be some airbrush action prior to that  .

I was just visualizing the model with possible colour schemes so the question, no compulsion please.   

When and where are you maiden the DRVIII ? would love to be there.
-Ponappa

@Ponappa
Thanks would need help as this will my first electric flight and a RC flight after a gap of over 5 years. Plan to fly this weekend but rains have started in Bangalore and expected for another 2 days. Praying for better conditions this weekend. Location not finalised yet. Could be in the cricket field in my son's apartment or Hoskote.

Yesterday was a bit unwell so just took the day off

very beautiful bird ,neat and clean creation.  

Today morning we did the "Maiden" at my sons apartment playground. The video is available on Youtube at the following link
The ground is rectangular but the wind was along the smaller width. The landing was in crosswind. I had the "Eagle Squadron" escort.

@Anwar
Any size restrictions for uploading video on the forum?

@ashok baijal
 
Flew right off the board!

Awesome flight
too windy i guess the plane is being carried of by the wind.

Congratulations! Great model

I've put the video here for you

@rcrcnitesh
The high towers around the playground make the place very gusty as wind blows through the gaps.

Ashok Sir Congratulations on the successful test flight. Flew beautifully 

Lovely flight ! Smooth sailing !! Cheers ...

Thanks  Need encouragement to continue building

Was under the impression that the Sweepstakes end on 15th April - just realised its 15th of next month - so what to build?

@ashok baijal
About a year back you had bought a trike/rogallo parts.
Build it.

Your view on this paint scheme 

Lovely. If you can do it without adding excess weight.

nice build. congrats for the successful maiden.
If u are already in Hoskote, it would have been better to do maiden at our regular flying area.

Dusted out my Fokker DR VIII and decided to give it a coat of paint. PROBLEM How to make the insignia of a bird (Post #80 above) that was there on the original? Any ideas?

One possibility -locate the pic  on google. Then, print on your home printer on photo paper. Cut it out, then glue on the fuse (SR 998 is a good option here) and cover with clear tape

Sanjayji, I have the picture but my inkjet cartridge is dried out. Its a Canon printer and not been able to locate a replacement. Tried filling it with fresh ink but again it did not work. I was planning to print it out on tracing paper but the shops where printing is done are not prepared to try printing on thin sheet.

Painting completed. Left out the bird emblem.