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www.ppgplans.com

– Do not duplicate or make public.

Last Revised Version: January 2010

Skybolt V2 – Construction Manual

Index

Page

Warnings & Disclaimer

Acknowledgements

Tools Used

Tips

Layout

Frame - Center Section

Building The Hoop

Lower Cage Section

Upper Cage Section

Hoop Connectors

Final Assembly

J Bars & Harness

Engine Mounts

Fuel Tank Mounting

Finish

Appendix A - More Photes

Appendix B – List of Materials

Appendix C – Other references

Содержание Skybolt V2

Страница 1: ...Property of www ppgplans com Do not duplicate or make public Last Revised Version January 2010 PPGPlans com Skybolt V2 Construction Manual Revised Version January 2010...

Страница 2: ...Warnings Disclaimer 3 Acknowledgements 3 Tools Used 4 Tips 4 Layout 5 Frame Center Section 6 Building The Hoop 9 Lower Cage Section 9 Upper Cage Section 11 Hoop Connectors 13 Final Assembly 17 J Bars...

Страница 3: ...and thorough preflight has been a contributing factor to accidents in all kinds of aircraft Equipment damage bodily injury even death can occur due to equipment problems not caught in a proper preflig...

Страница 4: ...bender Electric or cordless hand drill Hemostat straight 10 inch Files flat and round Various common hand tools Tips When drilling the inch holes in the square tubing extreme accuracy is necessary in...

Страница 5: ...cut an 18x48 inch piece and two 2x48 inch pieces off of one end From the two 2 inch strips cut a bunch of 2x4 inch blocks for hold down purposes later Center the 18x48 inch piece along the edge of th...

Страница 6: ...allow for precise alignment Tip On the bottom horizontal square tubes have the holes go all the way through both sides this way the steel on the vertical square tubes will have another anchor point to...

Страница 7: ...inches sticking out Insert two 2 chromoly tubes into the bottom of the vertical tubes leaving 1 inch sticking out 5 Temporarily install the two lower square horizontal tubes onto the bottom of the ver...

Страница 8: ...section lay the rest of the center section on the flat surface use blocks screwed down to hold in place make sure all joints are tight and all chromoly inserts are in place 7 Drill inch holes inch in...

Страница 9: ...aight line below the hoop circle 3 Slide this whole assembly side ways as needed until the 0 875 tube meets the inside hoop diameter line on your layout surface You may need to tweak the reference ben...

Страница 10: ...To make these curved hoop sections you are using the conduit bender to FORM the tube rather than bend the tube TIP It is fairly easy to straighten a tube that does not lay flat by inserting a tube in...

Страница 11: ...atch that the tube remains as straight as possible when it exits the bender keep it aligned with the handle of the bender 2 Once you have the two 0 750 sections formed lay them on the surface and scre...

Страница 12: ...nts are tight on both ends of the radial tubes check to make sure the side radial tubes are straight above the lines on the surface Also be sure the bottom of the center section is centered and remain...

Страница 13: ...ything is in place Mark the connector locations on both lower hoop tubes 2 Now remove the lower 0 875 hoop section Cut the lower 0 875 section off 1 inch above the connector outline Use a file and rou...

Страница 14: ...10 PPGPlans com 4 Insert the 0 750 tube at least 1 inch into the 0 875 tube you may need to reshape the ends of the tubes to accomplish this by squeezing them in a vise A small amount of grease works...

Страница 15: ...the center of the connector to mark the tube Drill a 7 32 hole on this mark through one wall of the tube only and bolt the connector to the tube using the half round anchor inside of the tube This is...

Страница 16: ...the end of the anchor is and mark it on the outside of the tube Mark and cut off the 0 625 upper tube to length Once again being sure the lower part of the center section is in place above the layout...

Страница 17: ...nch chromoly tube tight to the bottom square tubes Install the two AN4 24A bolts through the vertical tubes and the diagonal brace tubes with a large area washer on each side 2 Check that everything o...

Страница 18: ...it is a bit warped looking you may need to adjust the radial tube to hoop connectors by loosening them a bit and twisting that hoop section Once you are satisfied you can drill the 7 32 holes through...

Страница 19: ...t need to be closed tight only about halfway closed File all sharp edges nice and round this flat end will slide into the pocket on the harness webbing you want no sharp edges there For locating the p...

Страница 20: ...e through Slide the long straight part of the J bars into the protruding ends of the diagonal braces all the way to the bolt This can be a challenge as the J bar can be a tight fit in the square tube...

Страница 21: ...lic Last Revised Version January 2010 PPGPlans com Attach the lower end of the shoulder straps to the bottom part of the vertical square tubes Melt hole on the strap about 1 inch above the end attach...

Страница 22: ...to clear the starter can be cut with a jig saw with metal blade The dimensions for attaching these engine mounts are on the drawings Fuel Tank Mounting Use the 1 inch x 1 8 angle to mount the fuel tan...

Страница 23: ...eet the hoop You may want to add foam padding around the tubes at the bottom of the frame such as the 90 degree corner in the square tubing in case of contact with your legs Adding wheels at these cor...

Страница 24: ...Property of www ppgplans com Do not duplicate or make public Last Revised Version January 2010 PPGPlans com Appendix A More photos Pull Start pulley attached to side vertical bar Finshed Frame...

Страница 25: ...Property of www ppgplans com Do not duplicate or make public Last Revised Version January 2010 PPGPlans com Close up view of finished netting at the sides Finished Unit...

Страница 26: ...ft 6061 or 6063 aluminum square 1 x 0 125 wall square tube 2 3 ft sections 1 6ft section 1 2 ft section 6063 aluminum angle 1 x 0 125 angle 5 ft 6061 T6 aluminum round 0 875 x 0 058 wall 3 6 ft sectio...

Страница 27: ...co com Paratoys www paratoys com AerotThrust www aerothrustppg com Francesco De Santis www powerglider biz francesco powerglider biz Netting John Fetz botmom yahoo com Marc mcd0213 yahoo com Throttle...

Страница 28: ...Property of www ppgplans com Do not duplicate or make public Last Revised Version January 2010 PPGPlans com...

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