Canadian Flag Blowing In The Wind Ron Leclerc Zenith CH701 Construction Log


Zenair CH701 STOL Aircraft...
CH701 STOL

Winnipeg

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Rudder Position Light Construction Cont.!

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November 28, 2008
The position light ready to apply the fiberglass. A 1" flange will be allowed for... which will be needed to fasten the light onto the trailing edge of the rudder...

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December 7, 2008
Finishing Materials:
Water-based interior Flecto Varathane©...
Oil-based exterior semi-gloss Flecto Varathane©...
Oil-based Tremclad Aluminum paint...
Foam paint brush... which works great when applying the Water-based Flecto Varathane©...

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December 7, 2008
Start to apply fiberglass 6 oz cloth... used indoor water based Flecto Varathane© instead of any epoxy resin... surprised? Used this a lot when building my RC Models, especially for building foam floats with 1 oz fiberglass as a covering material.. Sets hard, flexible and easy to sand as compared to the epoxy resin...

 
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December 7, 2008
Start by applying fiberglass 6
oz cloth... waiting for water-based Varathane© to set. The nice thing about using the water-based Flecto Varathane©... is that it will set up in about an hour... there is no smell... and best of all easy to apply with the foam brush... and no problem cleaning up, just use water...

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December 7, 2008
Here is the position light... trimmed to shape and ready for final finishing. There will be 3 coats of water based Varathane© combined with baking powder and sanded with 180 and 440 wet sandpaper, and one last coat of 100% WPV applied with... no baking powder. The Varathane© and baking powder is combined...
3 parts Varathane© and one part of baking powder. Baking powder is added as a filler, to fill the natural weave for a nice finish. The last and final layer will be a coat of oil-based exterior semi-gloss Flecto Varathane©, before the paint is applied...

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December 11, 2008
Finished applying fiberglass with water based Varathane©, the filler, and 1 coat of the Oil-based exterior semi-gloss Flecto Varathane©... now ready for final painting. Will finish with 2 coats of Tremclad Aluminum paint... and then will apply a final coat of Oil-based exterior Flecto Varathane©. The Oil-based exterior semi-gloss Flecto Varathane© is great for applying over paint and will give it a finished look of real aluminum...

 
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December 13, 2008
Here is the position light trimmed to shape... for the light pattern needed. The 2" end piece has had the length adjusted to 1-3/8" to provide the the correct light pattern at the side and rear of the aircraft...

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December 13, 2008
The 1/8" aluminum mounting ring on the inside of the light at the aft "V" end of the rudder...

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December 14, 2008
Finished position light, ready for assembly and testing...

 
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December 14, 2008
Position light showing the bulb fixture installation...

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December 14, 2008
Here is the position light, working and tested with 12 volt battery, ready to be installed...

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December 14, 2008
Not bad for a first... cost about $10, the finish could be better. Ran out of the 1 oz fiberglass, so it was a little harder to finish... Next one will be better! ,

 

Construction Summary:

This Position Light is not that hard to make. Cutting the rudder "V" shape in the PVC is the most difficult procedure... you must try and keep the cut on the top and bottom the same... I made a pattern and and traced it on the PVC... top and bottom. For a first try I got lucky. The aft end of the light can be about 1-1/4" to 1-1'2" from the "V" where the mounting ring is to be installed... I started out with 2" which was a bit to much for the light pattern, has to be adjusted for the light pattern needed at the rear of the aircraft. It is best to not cut off to much, better to leave it little longer and adjust later. Instead of cutting it to short, make a(some) spacer(s) out of 1/8" 6061 like a washer and install between the mounting ring and the bulb fixture with a longer self-tapping #10 screw, also make sure that you are using the correct bulb size... a #93. This is just another way of adjusting the light pattern, probably easier. Now I used only 3 layers of 6 oz fiberglass. I should of used one more layer of 1 oz fiberglass(ran out) to give it a nice smooth finish, otherwise you have to use to much filler, which can make it quite heavy. The water-based Flecto Varathane© is very easy to work with, no muss, no fuss... sets up fast and very easy to clean with water. Its also best to apply a 100% coat of the interior water-based Varathane© over the final coat of the baking powder and Varathane© combo, as the first coat of oil-based paint can cook the baking powder... resulting in a bad surface. As a final coat over the Tremclad Aluminum paint... use oil-based Flecto Varathane© exterior semi-gloss. It gives it the real look of aluminum and provides for a good hard final finish... and saves you a couple hundred bucks.
There you have it, save the money and keep building...
 

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