The Volutera Cozy Mark IV Project #1504 by Alexandre Souto

Home ch04 ch05 ch06 ch07 ch08 ch09 ch13 ballistic hinge

 

Ch08 - Headrest, Heat Duct and Seat Belt

 

09/06/2008

One mould with a wood piece of the lower longeron.

A little plans deviation, I don`t like metals.

 

10/06/2008

Over the peel ply I laminated 1ply BID of carbon 3K @ 0/90, after one sequence of 7ply BID aramide KK205, alternating @45/-45 and 0/90.

On top 1ply BID carbon 3K.

12 hours of 15"Hg vacuum.

11/06/2008

After 8 hours ~80 Celsius sun indirect heater .

The four supports are light weight :

The 2024T3 is 3.175mm thickness, 1" in the eye and 2" length.

Mines are 3mm thickness that goes to 5mm when fixed in place with the extra glass.

The hold coattail is 1/2" that goes in the lower longeron and 1.25" the holed one. Length is 8,5cm or 3.34".

The piece is not the problem, only the 7 aramide plys holds one tension force of 1400kgf/cm.

The real problem is that the bolts head are fixed in the foam and fiber. Not a real good strength of these materials to support, They never fail, but I like my way to do that.

My angle is 55 degrees, against 90 degrees of the 2024 "L".

One chamfer in the lower longeron to be flush with the bottom.

Perfect.

Another shot.

Here the longeron is drilled and I put 3 SS pins of 1" at 1/4" from the edge.

The points are folding a little to hold the support.

The heads are trimmed to 3mm to go inside the bottom.

13/06/2008

Floxed in place.

Over the support more 2ply of aramide KK205, crossed 1" each side.

 

Photo.

15/06/2008

With the 2ply of aramide and trimmed, ready to receive the bottom.

21/06/2008

After the bottom is in place, I put 2 strips of carbon UNI over the longeron.

The 3 SS pins are perpendicular at UNI.

2ply BID of 3", over the longeron and the support.

29/06/2008

After the contour in ch07, we can see the base of the support.

I sanded 1mm of the base.

From top to down:

Pins hole in the bottom; Aramide bottom; Flox; 2ply aramide reinforcement; Support; Flox; Longeron; SS pins.

PS:The support is not ready. To hold one impact and to not get out of the longeron, I must to do more 10 layups of kevlar and glass extending the bottom and sides of the fuselage, at least 4".

 

 

Home ch04 ch05 ch06 ch07 ch08 ch09 ch13 ballistic hinge