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


Zenair CH701 STOL Aircraft...
CH701 STOL

Winnipeg

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Metric Converter

mm
ft
in

Note:
1 in = 25.4 mm
1 ft = 304.8 mm
1 ft = 12 in

 
 
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Vortex Generators VG's!

Wings VG's - Flat Skin Leading Edge!

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November 27, 2009
Patterns used to develop the blank cutting board... and the forming boards. Made out of 3/4" fir plywood. the pattern is 60mm x 30mm by 35mm. The VG is approximately 15mm high at the top point...

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November 27, 2009
VG Parts Blanks after cutting. 6061 T6 0.025 aluminum... 0.020 or 0.016 could also be used, your choice. The 0.025 is just a little more rugged...

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November 27, 2009
VG Parts Blanks formed into a part...

 
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November 27, 2009
VG Part nice and straight and ready to be deburred...

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November 27, 2009
A closer look at the newly formed VG Part...

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November 27, 2009
New VG part ready to be installed on wing...

 

Elevator VG's - Curved Skin Leading Edge!

Problem: A new tool had to be made to put a bend/curve in the VG to match the curved leading edge profile of the elevator.

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November 28, 2009
Add about 3/16"(setback) to the cut profile of the block... you can see the cut line on the block. The Block must be the same shape as the VG forming block... but 1/8" is added to the width. To form the block 2 pieces of 3/4" plywood are glued together to form one piece...

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November 28, 2009
Block after cutting with the band saw. Notice the amount of curve(setback) needed to form the VG curved surface...

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November 28, 2009
Block after cutting ready to be cut to the VG shape and base it will be glued to. Sand the upper and lower mating surfaces and apply a coat of alcohol and 5 min epoxy mixed together to get a hard surface...

 
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November 28, 2009
The block after cutting to VG shape will be glued to the square 3/4" base and then sandwiched between 2 end blocks for support...

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November 28, 2009
Note... that the lower block MUST be 1/8" wider then the upper block due to the width of the Vg in bent form. The upper block is then made narrower by the width of the VG forming block. Should be about 1/8" narrower, trim until it matches the formed VG part...

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November 28, 2009
There it is... a simple tool that works very well...

 
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November 28, 2009
Here is a formed VG ready to be bent to match the curved Leading Edge of the Elevator...

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November 28, 2009
Formed VG in place in the tool... ready to be bent. A 2x3 about 6" long can be used with a 2 lb hammer to bend the Vg. DO NOT hammer the upper block directly with the hammer, use the 2x3 it works great...

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November 28, 2009
A closer look at the tool and VG ready to be bent...

 
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November 28, 2009
There it is, a bent VG Part that is now ready to be installed on the Elevator...

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November 28, 2009
A closer look at the bent VG Part, it looks pretty good. Compare to Zenith's VG Part in the next photo...

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November 28, 2009
Zenith VG Part...
Compare the VG Part just made, to this VG Part... it is the one that Zenith is selling for a pretty hefty price...

 
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November 29, 2009
Zenith VG installation on the CH701 Elevator. The VG tip is located 120mm from the spar and 30mm spacing as recommended by STOLSPEED and since adopted by Zenith...

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November 29, 2009
VG making tools, can't get any simpler...

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November 29, 2009
VG Part Patterns needed, you can use your own dimensions, but 60mm x 30mm x 35mm and 15mm high seem to work ok...

 

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