tag:blogger.com,1999:blog-44288282017564229342024-03-05T04:22:39.288+08:00Scratch ArtisanFlybywire http://www.blogger.com/profile/12033050948969565462noreply@blogger.comBlogger7125tag:blogger.com,1999:blog-4428828201756422934.post-66483161578884851392023-07-09T15:55:00.000+08:002023-07-09T15:55:14.959+08:00Alpine ILX F509A floating Head Unit <p>The challenge is to mount this beautiful floating head unit (HU) onto my car. </p><p>But this car does not have factory brackets. It uses cage type to install single din. Alpine is also single din but cage bracket is too weak to support the 9 inch screen let alone trying to tilt it backwards. So 1.2mm Aluminium plate was chosen as a suitable material to make a suitable bracket. The bracket determines how far the floating display projects outwards from the car's cosmetic panel. I used cardboard to mark out its position and template it onto the car as a rough guide.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDPGSqCqoIEVb3kQDJYc0L-XSOgPoZk1fUjmXHFJdp7_KHZPAuxl7VepPHWRjRwExmQ4eMLjT4BtqZfevWdz0DDNAxJvLbx9rqr0uosSQtG-SZ0rAdCQ881CQeI5TtXRqe2idspCB09TD1y4o9Q9TXdG9ES5PWAnkJkRZHfb7kB6Xb_GEr6JUA0Dj1jK0/s4032/20230709_004524.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="1960" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDPGSqCqoIEVb3kQDJYc0L-XSOgPoZk1fUjmXHFJdp7_KHZPAuxl7VepPHWRjRwExmQ4eMLjT4BtqZfevWdz0DDNAxJvLbx9rqr0uosSQtG-SZ0rAdCQ881CQeI5TtXRqe2idspCB09TD1y4o9Q9TXdG9ES5PWAnkJkRZHfb7kB6Xb_GEr6JUA0Dj1jK0/w312-h640/20230709_004524.jpg" width="312" /></a></div><br /><div><br /></div><div>Alpine has 2 parts to install, one is the head unit and another display unit that connects it via a special connector . The 2 units are locked using 4 M5 screws. So the single cannot be mounted too far in or the screw driver will not be able to tighten the screws </div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwB_hETjn3yo2fk21PCNaxABlRdyDBjzMb--dcxhUiEEeQjZ2P7vT65Ak-6ih3sPfzR3JlQ2-3-_IgLW_dAUDpMFG7nSIG3D84bpQ2ht082OUUVd9F5Oyl500HHgZp5YMktzI_s-efMGy34_8FDeQ2N6rj4Z93XbYLCrQgGNoUoCiVU_NOQHnfVGFs9XY/s4032/20230627_231038.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1960" data-original-width="4032" height="312" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwB_hETjn3yo2fk21PCNaxABlRdyDBjzMb--dcxhUiEEeQjZ2P7vT65Ak-6ih3sPfzR3JlQ2-3-_IgLW_dAUDpMFG7nSIG3D84bpQ2ht082OUUVd9F5Oyl500HHgZp5YMktzI_s-efMGy34_8FDeQ2N6rj4Z93XbYLCrQgGNoUoCiVU_NOQHnfVGFs9XY/w640-h312/20230627_231038.jpg" width="640" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Test fit for easy access of screw holes <br /><br /></td></tr></tbody></table><div>Use cardboard again to estimate the size of the single din mounting bracket and cut it to size.</div><div><br /></div><div>Make M5 transfer screws to mark the single din mounting holes accurately.</div><div><br /></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhi391Yxvj_JYowSxFZGv5xvtAp1ZHMWaulm_naO-8ClDqzT0MCqoJgu8bjJjLPFeWRSBvM1ttXe67cYdf4T6ZDXFDcV_i1k5vD0O3QmYopWGAs7yL9fVF3Ru1h1z45xh7Ff3mv9Y0_x2I__8m0mEAArHCbFX3kBO9AELY15hzkmHQ1f8bFWikDNc_nlm0/s4032/20230617_235238.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1960" data-original-width="4032" height="312" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhi391Yxvj_JYowSxFZGv5xvtAp1ZHMWaulm_naO-8ClDqzT0MCqoJgu8bjJjLPFeWRSBvM1ttXe67cYdf4T6ZDXFDcV_i1k5vD0O3QmYopWGAs7yL9fVF3Ru1h1z45xh7Ff3mv9Y0_x2I__8m0mEAArHCbFX3kBO9AELY15hzkmHQ1f8bFWikDNc_nlm0/w640-h312/20230617_235238.jpg" width="640" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">4 transfer screws in place ready to mark</td></tr></tbody></table><br /><div><br /></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitBjmq1TeOPSCweFNLiyX633cH2IGAHf_4OZqYqtTrcjj7dWvcmWwd1AxoY_QofnZdEoY-jzJLirLdoC4xAzwfid0oQAo7fAjFqeA_blLNTvmTDGl5O7v8YHJj9pMHMcgPtJ0Xg0S4_G9Xgiv3ufthened2qRcXtnLprYKsP5hoWXxbvlKGB0XBY_iygA/s4032/20230709_103607.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="1960" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitBjmq1TeOPSCweFNLiyX633cH2IGAHf_4OZqYqtTrcjj7dWvcmWwd1AxoY_QofnZdEoY-jzJLirLdoC4xAzwfid0oQAo7fAjFqeA_blLNTvmTDGl5O7v8YHJj9pMHMcgPtJ0Xg0S4_G9Xgiv3ufthened2qRcXtnLprYKsP5hoWXxbvlKGB0XBY_iygA/w312-h640/20230709_103607.jpg" width="312" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Left and Right side templates</td></tr></tbody></table><br /><div><br /></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKqBEQOBTQySrSGS22Q4WaxOZ3FGM5BPGWk05sVex4J6WxIH-RHPOain6Oz7JG3E5tRf8QOhyFloNP4IPQ5c4S1rjrmAoxXQ4eSxnwZ-ecCAdwZlfqVcSAyRBwEFFcCJi-MOr3e5xBcN43McsrvWEEVeWFHb3_IpLVBOAyCTI00SZdqYuqmRGzOjE_CBk/s4032/20230626_124143.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="1960" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKqBEQOBTQySrSGS22Q4WaxOZ3FGM5BPGWk05sVex4J6WxIH-RHPOain6Oz7JG3E5tRf8QOhyFloNP4IPQ5c4S1rjrmAoxXQ4eSxnwZ-ecCAdwZlfqVcSAyRBwEFFcCJi-MOr3e5xBcN43McsrvWEEVeWFHb3_IpLVBOAyCTI00SZdqYuqmRGzOjE_CBk/w312-h640/20230626_124143.jpg" width="312" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Marking the holes accurately</td></tr></tbody></table><br />With the marked holes, drill to 5mm diameter and fit it onto the Alpine HU.<div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjAcIAWzt1z_4bgqLb6ok1fNFBQ4EX81Uj8zbRlHEXUxW9lBb2ph6XRaO4C9FfWPgWKvZRc3WlpI7145EDJED2-EsSVcBCf-wFxWPddr1BqJBVPzajAScBJdoXzthuImnu9L37jsJnXyamU15YJOeOLdMYg2H45nzp8-xSkL2ZKvorr2Cg6WIsbTYhr-7Q/s4032/20230628_120636.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1960" data-original-width="4032" height="312" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjAcIAWzt1z_4bgqLb6ok1fNFBQ4EX81Uj8zbRlHEXUxW9lBb2ph6XRaO4C9FfWPgWKvZRc3WlpI7145EDJED2-EsSVcBCf-wFxWPddr1BqJBVPzajAScBJdoXzthuImnu9L37jsJnXyamU15YJOeOLdMYg2H45nzp8-xSkL2ZKvorr2Cg6WIsbTYhr-7Q/w640-h312/20230628_120636.jpg" width="640" /></a></div><br /><div><br /></div><div>Use masking tape to mark out the excess material and remove </div></div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDcx86wcI4vib-8bVBGVrr902gRH-FJzQAM9mWVvpIpuselrcqhZgciYRXM268eAojEVaKuqk7-F3Cg8WK8XrC1Wlhx2YSqf3oJUphM4sKonT96BODK-hvXrIFaY2EbhQIdryhmow0PCuNJ87VKJPu9Xi7REeniVrhz8iBKCq4xvB4dyyGSClXehlSw24/s4032/20230625_151108.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="1960" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDcx86wcI4vib-8bVBGVrr902gRH-FJzQAM9mWVvpIpuselrcqhZgciYRXM268eAojEVaKuqk7-F3Cg8WK8XrC1Wlhx2YSqf3oJUphM4sKonT96BODK-hvXrIFaY2EbhQIdryhmow0PCuNJ87VKJPu9Xi7REeniVrhz8iBKCq4xvB4dyyGSClXehlSw24/w312-h640/20230625_151108.jpg" width="312" /></a></div><br /><div>Then mark the position of the mounting holes for the dash board panel using Acrylic material and transfer over to the mounting bracket.</div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXGFgkzHq8ngClMfZWYbCC-ZrUH2sS7uBvKyUvJb_wOI93ykYxIp0yy4zk8hXAj_usinbduSVYuk-DW1EGUoLQ5dy-HQ2ddMPa--CbIJvZO6_8WMBKoiMqPbLV1AGGThKPDRy856l4-5iC5-KWdTTyqdYSfimRvF7HSQ9bxK9SYv6hHOpkte6_8PN5aV8/s2268/20230627_182300.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1682" data-original-width="2268" height="474" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXGFgkzHq8ngClMfZWYbCC-ZrUH2sS7uBvKyUvJb_wOI93ykYxIp0yy4zk8hXAj_usinbduSVYuk-DW1EGUoLQ5dy-HQ2ddMPa--CbIJvZO6_8WMBKoiMqPbLV1AGGThKPDRy856l4-5iC5-KWdTTyqdYSfimRvF7HSQ9bxK9SYv6hHOpkte6_8PN5aV8/w640-h474/20230627_182300.jpg" width="640" /></a></div> <div>Before transferring the hole position, use a brake bender and bend the Aluminium bracket. <br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7vSefA2FeCysek3N1qQIrun4A85R3chUjw5W2INFXr-oYz85p1vZspr1Hl1MHLF7WiZzwW7_JBXSGTBIVjoQbadb8blLhh7CZmQe664M0C0E1eMNVoM2l8XEevneUKA7JE6MeKiYLhiZhVYPMy9KuKJVdedkKCZ5JEJUAZBP_eYeN8wPigZcUJ7Cx9lM/s4032/20230627_213707.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1960" data-original-width="4032" height="312" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7vSefA2FeCysek3N1qQIrun4A85R3chUjw5W2INFXr-oYz85p1vZspr1Hl1MHLF7WiZzwW7_JBXSGTBIVjoQbadb8blLhh7CZmQe664M0C0E1eMNVoM2l8XEevneUKA7JE6MeKiYLhiZhVYPMy9KuKJVdedkKCZ5JEJUAZBP_eYeN8wPigZcUJ7Cx9lM/w640-h312/20230627_213707.jpg" width="640" /></a></div><br /><div>Drill the Aluminium bracket and test fit.</div></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXFogLgdi2BBiC947W9jU6g5gWDh7ZqyLowNHMD0wUZwvzk651zEFzpNSCUoao9D4iqdH1rwOcamfX1qurl07UVYjniTm3SlG6hzjGq-xxsitsGs5ghgDGZCr7fPSKdNDc5vXEUIT8-mjkRIqgqu0_mYp11T39Jt-h7LtOhrOPPqE4s9HU913XJVUk-Zk/s4032/20230628_075351.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="1960" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXFogLgdi2BBiC947W9jU6g5gWDh7ZqyLowNHMD0wUZwvzk651zEFzpNSCUoao9D4iqdH1rwOcamfX1qurl07UVYjniTm3SlG6hzjGq-xxsitsGs5ghgDGZCr7fPSKdNDc5vXEUIT8-mjkRIqgqu0_mYp11T39Jt-h7LtOhrOPPqE4s9HU913XJVUk-Zk/w312-h640/20230628_075351.jpg" width="312" /></a></div><br /><div><br /></div><div>Mount the bracket onto the HU and pray that the mounting holes line up on the dash board.</div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8_Tn7K1CexwSLyBlgdYyUMsMWc5_Y1E4BBjcXH0zxUaStsYIkhrwpOJfP9leiX470arDyE906_L6WUI7feiaeuf0T0Ow2nI-xmDHq4h67NPb8tMTk0Myhky3A5xBcksH_KImkcKdrd4RVVqnr_R_xNVFe_sY3capLPXej_8oQ_wPsoIzO2CGLhpZqEcA/s4032/IMG-20230626-WA0001.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2268" data-original-width="4032" height="360" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8_Tn7K1CexwSLyBlgdYyUMsMWc5_Y1E4BBjcXH0zxUaStsYIkhrwpOJfP9leiX470arDyE906_L6WUI7feiaeuf0T0Ow2nI-xmDHq4h67NPb8tMTk0Myhky3A5xBcksH_KImkcKdrd4RVVqnr_R_xNVFe_sY3capLPXej_8oQ_wPsoIzO2CGLhpZqEcA/w640-h360/IMG-20230626-WA0001.jpeg" width="640" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Oops , this picture has no dashboard holes but you get the idea.<br /><br /><br /></td></tr></tbody></table><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgv2fUjKFGdLyv6YtiIsQJGvXF9POXx01gzI0DKxQCnoL5zuvbKSrtgoHKB20IDhqAvRiD8aY-5RrktSpbWqyQ81OBx7ofrYMgopFOtxjlSyEScvq5GX2qazPzOxhP-yxQ42q_7mgL6kMx1qJk7FRcrn9ytlPbHpApUR1vYM7eYoirObivATrMJzT0yoC8/s4032/20230629_234322.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1960" data-original-width="4032" height="312" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgv2fUjKFGdLyv6YtiIsQJGvXF9POXx01gzI0DKxQCnoL5zuvbKSrtgoHKB20IDhqAvRiD8aY-5RrktSpbWqyQ81OBx7ofrYMgopFOtxjlSyEScvq5GX2qazPzOxhP-yxQ42q_7mgL6kMx1qJk7FRcrn9ytlPbHpApUR1vYM7eYoirObivATrMJzT0yoC8/w640-h312/20230629_234322.jpg" width="640" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><br /></div>Then the big empty space at the top, just 3D print ABS and blank it off.<div class="separator" style="clear: both; text-align: center;"><br /></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQACAlmUJCxnAuY0eC3a_qwhl_-WD6bzUndL-G85uLVNhDmNMA1raZBlZXSxhH6VX37qMuIzLx7vYaJxo7h__Js2mH7xWT7DsODgq6vcfkH6p2Y-_BzTEw0lO4KSufirVWI61TtSQP62v8tLFd0BPF24izLftJCLVOr0hT2lulcKwgk2ssT8SUbKTGqV8/s4032/20230629_234259.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1960" data-original-width="4032" height="312" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQACAlmUJCxnAuY0eC3a_qwhl_-WD6bzUndL-G85uLVNhDmNMA1raZBlZXSxhH6VX37qMuIzLx7vYaJxo7h__Js2mH7xWT7DsODgq6vcfkH6p2Y-_BzTEw0lO4KSufirVWI61TtSQP62v8tLFd0BPF24izLftJCLVOr0hT2lulcKwgk2ssT8SUbKTGqV8/w640-h312/20230629_234259.jpg" width="640" /></a></div><br /><div>Assemble back all the cosmetic covers, cables and linkages. </div><div><br /></div><div>Do the wiring harness for the HU and plug it in.</div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZBDJWKYaN7J3UNO8DZleJYXeMR9VjiyOJEdyZ3GxRHKky-6oOoGGul9Wk1vWzz9HpBf_wt16HB-qBP2lJRzol3b3hmWP34pyhgzoc1s8zk9_-ZrN_3rV0US_gjHcLQvm6_UHNwBVWBqyucdpBiZJJX9tOWMji8zuoeyXh-tKPZgrtRsIrt_0zZia3lUk/s4032/IMG-20230629-WA0012.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2268" data-original-width="4032" height="360" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZBDJWKYaN7J3UNO8DZleJYXeMR9VjiyOJEdyZ3GxRHKky-6oOoGGul9Wk1vWzz9HpBf_wt16HB-qBP2lJRzol3b3hmWP34pyhgzoc1s8zk9_-ZrN_3rV0US_gjHcLQvm6_UHNwBVWBqyucdpBiZJJX9tOWMji8zuoeyXh-tKPZgrtRsIrt_0zZia3lUk/w640-h360/IMG-20230629-WA0012.jpeg" width="640" /></a></div><br /><div>This HU has no dimmer wire . It has a light sensor in front of the screen to detect light and auto dims the screen at night.</div><div><br /></div><div>Adjust the height of the screen and fit it to the HU. Power up and enjoy.</div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMbkYR5z5WLCW6FQ2rnWL9otaqhvsldIv0ulEPSwM1egLCWDjGxogcENvtDlLMAxSOltEGsz7_IVsGSL9gN_Vac5tSAmrBUOGsjKI822cjynPK9nuBzLE3SUQfKG6brq-czhrbLfGk-FoX44MdiN0y_-ZEey7DzDn1FV3yn47-2GqSt5_LLxY4Dev5wYo/s4032/20230702_110619.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="1960" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMbkYR5z5WLCW6FQ2rnWL9otaqhvsldIv0ulEPSwM1egLCWDjGxogcENvtDlLMAxSOltEGsz7_IVsGSL9gN_Vac5tSAmrBUOGsjKI822cjynPK9nuBzLE3SUQfKG6brq-czhrbLfGk-FoX44MdiN0y_-ZEey7DzDn1FV3yn47-2GqSt5_LLxY4Dev5wYo/w312-h640/20230702_110619.jpg" width="312" /></a></div><br /><div>TURN the key to ACC position and watch the magic happens on the 9 inch screen. Music playback is done at 96khz sampling at 24 bits!! Mind blowing sound and every musical instrument can be heard clearly.</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDVktOZFmWVP5BOF375iE2-pJVU7NxJmD-GIcZlmBFDw1JjJjUjmlr51xN1t7RrwNFESmKfZy3fo-qFPaHxqxEUE5e0oUWMFkiC9eMuPJJyw8_TGZjyZJN3zAv0c7vV3nusfJKI8PecNaq7QOHYF9MJYu7rlpI3ALdM1Ay_00xirutM1AvM-_ZSrjkuZ4/s4032/20230702_164437.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1960" data-original-width="4032" height="312" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDVktOZFmWVP5BOF375iE2-pJVU7NxJmD-GIcZlmBFDw1JjJjUjmlr51xN1t7RrwNFESmKfZy3fo-qFPaHxqxEUE5e0oUWMFkiC9eMuPJJyw8_TGZjyZJN3zAv0c7vV3nusfJKI8PecNaq7QOHYF9MJYu7rlpI3ALdM1Ay_00xirutM1AvM-_ZSrjkuZ4/w640-h312/20230702_164437.jpg" width="640" /></a></div><br /><div><br /><div>The difficulty of this project is high. It involves precision mounting and drilling the holes exactly where it should be. You can drill oversize holes but with experience, the holes can be spot on and the mount is more secure and stable. </div><div><br /></div><div>AERPRO sells third party Fascia mounting brackets but its all rubbish. When you try to tilt and adjust the screen, the whole assembly will break loose and don't forget its a moving car with lots of vibration.</div><div><br /></div><div>DONE!!!</div></div>Flybywire http://www.blogger.com/profile/12033050948969565462noreply@blogger.com0tag:blogger.com,1999:blog-4428828201756422934.post-19463405454237172012021-08-06T12:43:00.004+08:002021-08-06T19:40:12.188+08:00I.C.E. system ( In Car Entertainment)<p>It started with a cranky faulty HU (Head Unit) and the MP3 player could not play. Quickly replaced it with Double Din HU. Out comes the climate control panel and all the cable and electrical clips. If you are doing this yourself , go slow and undo the clips and be patient. Access to the old HU will be possible. Only 2 screws holds the HU in place. New brackets were made for the Double Din HU. The matching wire HG harness was soldered to enable the quick release feature for future retrieval.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjV1VembkytUaC1mB8bcM2wHzJoah8DEPufOrjwiAvJ4jwLLT4PqJEzFOqxIIVw6KfKaESWJ5sX_dWyIhFxIFSZ0jMmHlpNpZ9YculqhiOER8YzaiUgzdfifGNlVVR2lC2O5XKZQeUUfBc/s2543/20210402_092420.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1236" data-original-width="2543" height="156" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjV1VembkytUaC1mB8bcM2wHzJoah8DEPufOrjwiAvJ4jwLLT4PqJEzFOqxIIVw6KfKaESWJ5sX_dWyIhFxIFSZ0jMmHlpNpZ9YculqhiOER8YzaiUgzdfifGNlVVR2lC2O5XKZQeUUfBc/s320/20210402_092420.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;">Top is supplied with HU purchase</div><div class="separator" style="clear: both; text-align: center;">Bottom harness is connected to factory wire harness</div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJRqVuV5cUOhnxqnSxDJKUxEewkZpMHXf4y7iuslZg6KODfCbS0AMpPYVZWC1jaT-iCC2hNvaXzmF1MTQEXEwHbYUXuC_bLbH9R8Uoyk_2gIXcbPG7wXkgFGCqN2VFBL3T3FVD2VqHzAQ/s2543/20210402_220622.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1236" data-original-width="2543" height="156" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJRqVuV5cUOhnxqnSxDJKUxEewkZpMHXf4y7iuslZg6KODfCbS0AMpPYVZWC1jaT-iCC2hNvaXzmF1MTQEXEwHbYUXuC_bLbH9R8Uoyk_2gIXcbPG7wXkgFGCqN2VFBL3T3FVD2VqHzAQ/s320/20210402_220622.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbsnj8IFCRAmN7Y0LN9LmoIymRNQ2en6xnUN6zjaz4cf-ZEf46qG4d5jguLeIYYw7SWiTAtP4EVinluVvKhH_XhOLGEYyJQisaRO2I2gWFM2oKxEkFCn32e20gUeTzTxm6tMTaQo5bstE/s2048/IMG-20210405-WA0003.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1152" data-original-width="2048" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbsnj8IFCRAmN7Y0LN9LmoIymRNQ2en6xnUN6zjaz4cf-ZEf46qG4d5jguLeIYYw7SWiTAtP4EVinluVvKhH_XhOLGEYyJQisaRO2I2gWFM2oKxEkFCn32e20gUeTzTxm6tMTaQo5bstE/s320/IMG-20210405-WA0003.jpeg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;">The old stereo and pocket to keep rubbish</div><div class="separator" style="clear: both; text-align: center;"><div class="separator" style="clear: both; text-align: center;"><br /></div></div><p>Be prepared for many trial and error fitting with the custom brackets. Fit in the new HU and reuse the old screws to secure it in place.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTAGDbKGs9xycLjY8tRQu3T3cdBAorej7v_YtE4EEVjU1Ry4Gl5ZMaSUlyEdZYdsg8_r3bRdouAMfHa9w7XyJKVDMcVqmWuGhIrEi6W5kKxzUf9NfZunxAIbKRh4WGaXFwJ9j1E-Oe88Q/s2543/20210403_082914.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2543" data-original-width="1236" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTAGDbKGs9xycLjY8tRQu3T3cdBAorej7v_YtE4EEVjU1Ry4Gl5ZMaSUlyEdZYdsg8_r3bRdouAMfHa9w7XyJKVDMcVqmWuGhIrEi6W5kKxzUf9NfZunxAIbKRh4WGaXFwJ9j1E-Oe88Q/s320/20210403_082914.jpg" width="156" /></a></div><div class="separator" style="clear: both; text-align: center;">Poor man's helper hands to solder the two together. I don't like to cut off the factory wiring. </div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiuA7c_vDFuAuUOylg8wkXffVv7BzIbiZ-_9d-gh1iksDZwqL8FYYoSYraDFipJel8SUo7eJaRo5LMkzIRQJFwsj_jqOqh521_JnM6B4w2e82KOhZ7kffvLrBJbCRYureTRzKaDEc475cg/s2543/20210403_110347.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1236" data-original-width="2543" height="156" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiuA7c_vDFuAuUOylg8wkXffVv7BzIbiZ-_9d-gh1iksDZwqL8FYYoSYraDFipJel8SUo7eJaRo5LMkzIRQJFwsj_jqOqh521_JnM6B4w2e82KOhZ7kffvLrBJbCRYureTRzKaDEc475cg/s320/20210403_110347.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;">Soldered wire</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_JDj4iJcxGuSOot0wNSfrzkufbtjfip2ZZeF7R19E-99-pRdX4kCU7CcwZcBPlZcHAmAS3W0PZ9DUtPPa9sCK9DUm4lJ8Qw2yJFjIT_mMxq8TjPXnnfs6fut4WD1fmL9FG41iZBeuG80/s2543/20210403_154012.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2543" data-original-width="1236" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_JDj4iJcxGuSOot0wNSfrzkufbtjfip2ZZeF7R19E-99-pRdX4kCU7CcwZcBPlZcHAmAS3W0PZ9DUtPPa9sCK9DUm4lJ8Qw2yJFjIT_mMxq8TjPXnnfs6fut4WD1fmL9FG41iZBeuG80/s320/20210403_154012.jpg" width="156" /></a></div><div class="separator" style="clear: both; text-align: center;">Completed new wire harness </div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikVxDpUNyQGPsdjo8dJd2n-NAblwHy3W56kZwy11El8aQNVMvq_VdEj7mPgT8S7DqckfOULg7Mc0aUU9I50g1NG3dj525n8olTBHVTPHZ782jiUJ5dTk1jjmLe4-eQwt4_I2jUwt-9K04/s2543/20210403_160604.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2543" data-original-width="1236" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikVxDpUNyQGPsdjo8dJd2n-NAblwHy3W56kZwy11El8aQNVMvq_VdEj7mPgT8S7DqckfOULg7Mc0aUU9I50g1NG3dj525n8olTBHVTPHZ782jiUJ5dTk1jjmLe4-eQwt4_I2jUwt-9K04/s320/20210403_160604.jpg" width="156" /></a></div><div class="separator" style="clear: both; text-align: center;">Clip in the new harness, original factory </div><div class="separator" style="clear: both; text-align: center;">wires are not cut </div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizF32YoLpHU2ZgfiK1eBDKJIXTNb0XwNJdpLoIezokVeUniZ26Xuq_UCNpt3mc5g_l2PVCOVPT1r097_qtVcsgZmb46H50QGYpOn5h4yaQhFvF6qO8lWaMMQy9OGjWsbS67fzoPuWTi9E/s2543/20210403_160611.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2543" data-original-width="1236" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizF32YoLpHU2ZgfiK1eBDKJIXTNb0XwNJdpLoIezokVeUniZ26Xuq_UCNpt3mc5g_l2PVCOVPT1r097_qtVcsgZmb46H50QGYpOn5h4yaQhFvF6qO8lWaMMQy9OGjWsbS67fzoPuWTi9E/s320/20210403_160611.jpg" width="156" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvf0mdHMhbyA0ZbW4Lb6ooYB5hHCLvK9hAIRmTl7T-LiBVGNiSrAWRQxbg3kCObOd2z1Mes_TpmwHLinzsWSHR0-iLJAdVaPCJjYNGW-bFO4IkGs0_mqXxGpJqZwUvA3Yo0axMtmzmyZ8/s2543/20210403_171149.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1236" data-original-width="2543" height="156" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvf0mdHMhbyA0ZbW4Lb6ooYB5hHCLvK9hAIRmTl7T-LiBVGNiSrAWRQxbg3kCObOd2z1Mes_TpmwHLinzsWSHR0-iLJAdVaPCJjYNGW-bFO4IkGs0_mqXxGpJqZwUvA3Yo0axMtmzmyZ8/s320/20210403_171149.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;">Fit in the new HU </div><div class="separator" style="clear: both; text-align: center;">and reuse the self tapping screws</div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: left;"><br /></div>Power up the unit and its a success. But wait .... to make the installation with a factory look, you will need a Fascia cover. Just 3D print a carbon fiber one and put it on.<div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjX1z79qXm7F47Pveguu0qXu6Wyy7999LM6ykAiInWiJAw8do_2UI0c702HU2XyLnEJUn2KLVHe2gYP3rWuQWj92iKLqepWCsOPB9buU1T5r3iTn7sI6FIer8E2elT1CM7dV8obFfr_620/s2543/20210403_171712.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2543" data-original-width="1236" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjX1z79qXm7F47Pveguu0qXu6Wyy7999LM6ykAiInWiJAw8do_2UI0c702HU2XyLnEJUn2KLVHe2gYP3rWuQWj92iKLqepWCsOPB9buU1T5r3iTn7sI6FIer8E2elT1CM7dV8obFfr_620/s320/20210403_171712.jpg" width="156" /></a></div>Custom made fascia with factory looks.</div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: left;">AMPLIFIER 4 SPEAKER CROSS OVER INSTALLATION </div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;">Not too long later, the rear oval shaped factory speaker surround material that holds the cone disintegrated and the speakers sounded terrible. Out goes the old ones held on by just 4 screws. But the new ones are 6.5 inch round ones so an adapter plate is required for a successful mount. I 3D printed one and was happy with the results. Soon it failed and wrapped under the sun so i made 1.2mm thick aluminum sheet. This was CNC cut out to reduce distortion. </div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4clqeUeUI4y0mFXHCJTmGi2d29XWRAoBSUXoIISEfxV9RNYCll9Du6bx6n-EEyM19_CX-PePAjZOId3DdHm_e6ipYwsXo8u8Z1vpab2wseG9Y6aCANSH39OMib4wSWFXyQwM-PzvHMMw/s2048/IMG-20210526-WA0002.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1152" data-original-width="2048" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4clqeUeUI4y0mFXHCJTmGi2d29XWRAoBSUXoIISEfxV9RNYCll9Du6bx6n-EEyM19_CX-PePAjZOId3DdHm_e6ipYwsXo8u8Z1vpab2wseG9Y6aCANSH39OMib4wSWFXyQwM-PzvHMMw/s320/IMG-20210526-WA0002.jpeg" width="320" /></a></div><div style="text-align: center;">Blue color plastic 3D print. Wrapped under the sun.</div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8SjGVcOE7LJd5dVa7VsNQPbkHI_FteH3R0qZMxqEpQ62NPWFLIk_LhGBeYuzv3yAEtnsZakECyZ1zmeYIMuli0BhX4o1noWuyaucasZhOiw_LG2NWnj0xHePTJWIVbWuZcj2h19tBlUc/s2543/20210712_200426.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2543" data-original-width="1236" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8SjGVcOE7LJd5dVa7VsNQPbkHI_FteH3R0qZMxqEpQ62NPWFLIk_LhGBeYuzv3yAEtnsZakECyZ1zmeYIMuli0BhX4o1noWuyaucasZhOiw_LG2NWnj0xHePTJWIVbWuZcj2h19tBlUc/s320/20210712_200426.jpg" width="156" /></a></div><div class="separator" style="clear: both; text-align: center;">CNC machined out. No wrapping </div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgMIdBFAWkZwLEP3kQ9Rx_o9IWMj-4J1-M975MZbkyjHca-nogU6BL20taXWHuPqqUdEnOY1dSsEiWd0nKBsRNMycLkba2j05D_D2Uk9cj7CI1mOrwaEyESNEJBwmn1Iq8mGRuxADUYmT4/s2543/20210712_230156.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2543" data-original-width="1236" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgMIdBFAWkZwLEP3kQ9Rx_o9IWMj-4J1-M975MZbkyjHca-nogU6BL20taXWHuPqqUdEnOY1dSsEiWd0nKBsRNMycLkba2j05D_D2Uk9cj7CI1mOrwaEyESNEJBwmn1Iq8mGRuxADUYmT4/s320/20210712_230156.jpg" width="156" /></a></div><div class="separator" style="clear: both; text-align: center;">Perfectly aligned holes and curvature</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDYgIQV4dlThsOScsDWzhKiOsq25BiOmasUsOSFkQSpH23YlS7OmVcxzYDZ22GKNTGoWeUhRiNvLlBhSDcZuscGz4Re0rRW7vWE7Qb-FQcWU45m-ZzVOqunwE36CKPegNs6-riDQWpKBg/s2543/Right+side+mounted.jpg" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" data-original-height="1236" data-original-width="2543" height="156" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDYgIQV4dlThsOScsDWzhKiOsq25BiOmasUsOSFkQSpH23YlS7OmVcxzYDZ22GKNTGoWeUhRiNvLlBhSDcZuscGz4Re0rRW7vWE7Qb-FQcWU45m-ZzVOqunwE36CKPegNs6-riDQWpKBg/s320/Right+side+mounted.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;">Dry fit. Looks damn good </div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: left;">WIRE INSTALLATION</div><div class="separator" style="clear: both; text-align: left;"> </div><div class="separator" style="clear: both; text-align: left;">The nightmare is about to start. 2 wires for rear speakers, 2 wires for front speakers, 4 RCA for the 4 channels and one big wire for the power to the amplifier. One more wire to REM</div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;">REAR WIRES</div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;">The rear seats , all cosmetic covers in the trunk and cabin areas were removed to make way for the wire layout. Rear wires were easy but they need to tuck under the floor carpet for aesthetic reasons. I use laundry lines to help thread the wires through. <div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimVcsBd1axfCtPnGFVIou6iAiyByUr97Bu4Q_y7g2DKpL4vytkywsdy1xiiU8fd5LK6yeU79kAUKbkqeQtTOC3fql6S44c9MvMjlWDjXX4A3uvloGzQcR9javwahhpsfDQx-F_D1HtwvA/s2543/Threading+rear+wires.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2543" data-original-width="1236" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimVcsBd1axfCtPnGFVIou6iAiyByUr97Bu4Q_y7g2DKpL4vytkywsdy1xiiU8fd5LK6yeU79kAUKbkqeQtTOC3fql6S44c9MvMjlWDjXX4A3uvloGzQcR9javwahhpsfDQx-F_D1HtwvA/s320/Threading+rear+wires.jpg" width="156" /></a></div><div class="separator" style="clear: both; text-align: center;">Green leader line leads the way</div><div class="separator" style="clear: both; text-align: center;">Tape the speaker wires and pull through.</div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnuSRRB7ZQ2056LmyU7372g-7FqnNqFFxpxq5YHD_pOLeyuZaGZKdw8vTP-LvzM5aY29nNRstHmmSkqYa2gKhOwC1dZpR6AOjgn4ltgXpHu9j4y7BcuzbtfQQUuwQ5D_icJh5_-Dl8zLk/s2543/20210717_110413.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2543" data-original-width="1236" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnuSRRB7ZQ2056LmyU7372g-7FqnNqFFxpxq5YHD_pOLeyuZaGZKdw8vTP-LvzM5aY29nNRstHmmSkqYa2gKhOwC1dZpR6AOjgn4ltgXpHu9j4y7BcuzbtfQQUuwQ5D_icJh5_-Dl8zLk/s320/20210717_110413.jpg" width="156" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgW4KdEwxTedCa4JQ6QThGOzt3hBD5mHsaN4AT_akZx0JyaRjGLIJnwKUmhimSkaW1IsAPSa39cuEAjRwIibMuC6TsLpA71BzhLOGZUCiIQDOgi6rCScdjLgztNlAq24JQxbCfXUtGPgfQ/s2543/20210716_181435.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2543" data-original-width="1236" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgW4KdEwxTedCa4JQ6QThGOzt3hBD5mHsaN4AT_akZx0JyaRjGLIJnwKUmhimSkaW1IsAPSa39cuEAjRwIibMuC6TsLpA71BzhLOGZUCiIQDOgi6rCScdjLgztNlAq24JQxbCfXUtGPgfQ/s320/20210716_181435.jpg" width="156" /></a></div></div><div class="separator" style="clear: both; text-align: center;">Tape together with factory wires and make sure the wires clear the cosmetic cover's snap clips</div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: left;"><br /></div>FRONT WIRES<div><br /><div>This one was tough. There's no way into the cabin from the door and the factory makes dedicated plugs with rubber boots to keep out the water. Many would thread the speaker's wire here. But using 16 Awg wire for me just wouldn't work. I starred at the problem for a good 45minutes before i saw the solution. Its not made known to the public but the manufacturer made a square opening at the hinge pin that leads back to the cabin. Water is not able to get in because of the door's weather rubber strip. Here's the chance. Its a tight squeeze for the speaker wires as well as the tweeter wires. Rubber grommets were use to prevent the sharp chasis from cutting the wires.<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgr__SLwueRi2ADaOjq_SPhdnEuFJ3u0kLkZ9JVCnjdHew7py2J0BsjxSiC7Q_Tx8Zy8OfI19PJPHlEhiAf89KSfVPgQFORcYF3B20y_82X8-9LqxJqzDNQYJiO0n50MhO_7ifaGt5XTrc/s2543/Threading+speaker+wire+thru+door.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1236" data-original-width="2543" height="156" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgr__SLwueRi2ADaOjq_SPhdnEuFJ3u0kLkZ9JVCnjdHew7py2J0BsjxSiC7Q_Tx8Zy8OfI19PJPHlEhiAf89KSfVPgQFORcYF3B20y_82X8-9LqxJqzDNQYJiO0n50MhO_7ifaGt5XTrc/s320/Threading+speaker+wire+thru+door.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;">That's the only hole back to the cabin.</div></div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: left;">Center console was removed to make way for the wire on the right speaker to travel back to the amp. <div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgJk77iXLocpqPSprE65BVAdXUVnXHM7Oee5iVwpaVNM2qb3TBn9U2_t5kduGLfukM-QLNy1cC3HoFQ8M2kk_ryH7bfnm2UupqxGyBTsC7lg50GgP1yHaFpeMvSA2GzfoWdXDml8lPiyX0/s2543/20210724_160454.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2543" data-original-width="1236" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgJk77iXLocpqPSprE65BVAdXUVnXHM7Oee5iVwpaVNM2qb3TBn9U2_t5kduGLfukM-QLNy1cC3HoFQ8M2kk_ryH7bfnm2UupqxGyBTsC7lg50GgP1yHaFpeMvSA2GzfoWdXDml8lPiyX0/s320/20210724_160454.jpg" width="156" /></a></div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;">BATTERY POWER CABLE</div><div class="separator" style="clear: both; text-align: left;"><br /></div>So the last piece of wire, the power cable, must be connected to the battery and goes into the cabin area and connect back to the amp. </div><div class="separator" style="clear: both; text-align: left;">I looked for existing grommet that the factory has left behind so that I can fit the 4AWG wire past the firewall but there isn't one. Finally there was just one but at the left hand side of the car just before the A pillar.</div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;">Fenders and mud guards were removed to route this thick wire in. Get the quality flexible multi strand wires to make the job easier. </div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgi8l6FXNVd6z2ewlyYCxSvp3vdRg19wToVmOckLj6I6ndpKqQFaij6tBwn3qODEBXBJCxwy5zrfuxH_FUkmuRVeXJgAXSdA2iybT02ICb4aysSYJ1wi_Hp2EFsto-fIE6QFj6WUD2OX8s/s2543/20210726_111209.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1236" data-original-width="2543" height="156" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgi8l6FXNVd6z2ewlyYCxSvp3vdRg19wToVmOckLj6I6ndpKqQFaij6tBwn3qODEBXBJCxwy5zrfuxH_FUkmuRVeXJgAXSdA2iybT02ICb4aysSYJ1wi_Hp2EFsto-fIE6QFj6WUD2OX8s/s320/20210726_111209.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;">Remove fender and headlights </div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZZlphnmE2DQtVQ9gkopS5PjFoLu8R94RX_aZHU6DrnzU17aMHQ_SxIGp2PAsO6PVezFSh29zRRYtdETYEtdxGl2pYXRzTaf-m23eS7r4aX41d_E0xebpWLH4_0KW4twEnZ601OcJ5R0Q/s2543/20210726_164636.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1236" data-original-width="2543" height="156" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZZlphnmE2DQtVQ9gkopS5PjFoLu8R94RX_aZHU6DrnzU17aMHQ_SxIGp2PAsO6PVezFSh29zRRYtdETYEtdxGl2pYXRzTaf-m23eS7r4aX41d_E0xebpWLH4_0KW4twEnZ601OcJ5R0Q/s320/20210726_164636.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;">Power cable zip tied for safety</div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjK2n1MBPdNQdWyEwO0SYKyb3w-vrfTS-qBLD26mLR8w_RmiGhGzS5MGE5gw1sVvat_C5hvZjfxeVp1dXWVxgbR2SBbUgvOEf23FUUjoHsPYuobfCKJ3g-R1X6yP-_xjITvd1DwiLHtUME/s2543/Left+Fender+wiring+.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1236" data-original-width="2543" height="156" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjK2n1MBPdNQdWyEwO0SYKyb3w-vrfTS-qBLD26mLR8w_RmiGhGzS5MGE5gw1sVvat_C5hvZjfxeVp1dXWVxgbR2SBbUgvOEf23FUUjoHsPYuobfCKJ3g-R1X6yP-_xjITvd1DwiLHtUME/s320/Left+Fender+wiring+.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;">From cabin out to battery terminal </div><br /><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;">Terminate the wires with quality copper sleeves, crimped spade connector and 60A fuse box.</div><div class="separator" style="clear: both; text-align: center;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmVngWbSRxBh_84f_q6-n0EKyor7zko60RLoA8UWi5azamzdnLR5o0n5ND80cP8q0vRn3qyf_Iweo3-c0AeJGX2yr1c39BZS-aprThPZr8iq1dZyByhKDgUrM4GnVLH7J_5VaXVLSzsHM/s2543/20210727_135211.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2543" data-original-width="1236" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmVngWbSRxBh_84f_q6-n0EKyor7zko60RLoA8UWi5azamzdnLR5o0n5ND80cP8q0vRn3qyf_Iweo3-c0AeJGX2yr1c39BZS-aprThPZr8iq1dZyByhKDgUrM4GnVLH7J_5VaXVLSzsHM/s320/20210727_135211.jpg" width="156" /></a></div><div class="separator" style="clear: both; text-align: center;">Spade connector to +ve battery end</div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjjsdO5hV1K0vlw0oAhGxocbPlEdej8d_vltKzKIALzUHEsY9rWCc6ffgOJAuJypRwOtRN6hWJSG32XiIdYSBN5xMvVFOheYJxYmlIE_EuN9SRQGTKr_rQ9Z0by54AWJaT2FUydugyY2E/s2543/20210727_162336.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2543" data-original-width="1236" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjjsdO5hV1K0vlw0oAhGxocbPlEdej8d_vltKzKIALzUHEsY9rWCc6ffgOJAuJypRwOtRN6hWJSG32XiIdYSBN5xMvVFOheYJxYmlIE_EuN9SRQGTKr_rQ9Z0by54AWJaT2FUydugyY2E/s320/20210727_162336.jpg" width="156" /></a></div><div class="separator" style="clear: both; text-align: center;">More than 200 strands of fine copper and flexible rubber insulator.</div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbw-lpzOUyiGSi3gUJeDnWv9mt30Z-aOf19JSiyJTd9sUFQ_1ypI3lGLxaB1xOXhwHcvz-xcgDzpojZzcnZM9SrsC0TiKfq_1RTenEXAGs8jrlEQlY0mZobPOxpjWsjnZLFmCm-rwXQEE/s2543/20210727_165028.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2543" data-original-width="1236" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbw-lpzOUyiGSi3gUJeDnWv9mt30Z-aOf19JSiyJTd9sUFQ_1ypI3lGLxaB1xOXhwHcvz-xcgDzpojZzcnZM9SrsC0TiKfq_1RTenEXAGs8jrlEQlY0mZobPOxpjWsjnZLFmCm-rwXQEE/s320/20210727_165028.jpg" width="156" /></a></div><div class="separator" style="clear: both; text-align: center;">Copper sleeve and solder added</div><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjj5cCVbG_OYmiTD2CeYNzqfjXF8_dmJw-jOAsQjNmD66S6TByr_h_hNVtR126M2_rQZrTanYfTwh3AWnYY8tT5XYJaU07IeyDfJafmRfJwjnogxmIdGhFoMIFaRUbPtMyJXEcMAiemzRU/s2543/20210727_165712.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2543" data-original-width="1236" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjj5cCVbG_OYmiTD2CeYNzqfjXF8_dmJw-jOAsQjNmD66S6TByr_h_hNVtR126M2_rQZrTanYfTwh3AWnYY8tT5XYJaU07IeyDfJafmRfJwjnogxmIdGhFoMIFaRUbPtMyJXEcMAiemzRU/s320/20210727_165712.jpg" width="156" /></a></div><div class="separator" style="clear: both; text-align: center;">Bad ass 60A fuse box added</div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: left;">REM WIRE</div><div><br /></div><div>This is the wire that turns on the Amp when the HU is activated. It sends +12v to AMP remote turn on terminal. Its like a switch but controlled by the HU.<div>Its a small wire so i use a small connector and added another copper sleeve for assurance.</div><div><br /></div><div>TERMINATING SPEAKER WIRES</div><div><br /></div><div>To get the best sound and years of trouble free stereo, use proper connector. Here proper crimping technique is also applied.<br /><div class="separator" style="clear: both;"><br /></div></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkZ0jqYWN7xGtDtILAXTJa5uCj-1K_wQirGcjyTQwxhYk7iI4vTARYWM2NAM0Vw_zLCg-rT4cXKhM-hAw0S4JsgRHpOUJJCgbL6C7uybxgVBoxo1kw61fveHIBUksbFaDZtFXT6EHjBHY/s2543/Front+Right+wiring.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1236" data-original-width="2543" height="156" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkZ0jqYWN7xGtDtILAXTJa5uCj-1K_wQirGcjyTQwxhYk7iI4vTARYWM2NAM0Vw_zLCg-rT4cXKhM-hAw0S4JsgRHpOUJJCgbL6C7uybxgVBoxo1kw61fveHIBUksbFaDZtFXT6EHjBHY/s320/Front+Right+wiring.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;">Spade connector and insulating sleeve. Cross over tweeter wires connected as well </div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjlH9Lc1qgjIFuSfzR_qqJU66R_BMEH4bdosa06nuu-DXoBSG3szTcHAEjKq-fxHZYOQBgk9xY7wN1ml9mhtTR8tEWp_3Lj4v-0xGfbgJG7G8qeOmSCbe4aEMWU1UP6ah2Bv2mNDbCPty8/s2543/Zip+tie+terminal+cables.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2543" data-original-width="1236" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjlH9Lc1qgjIFuSfzR_qqJU66R_BMEH4bdosa06nuu-DXoBSG3szTcHAEjKq-fxHZYOQBgk9xY7wN1ml9mhtTR8tEWp_3Lj4v-0xGfbgJG7G8qeOmSCbe4aEMWU1UP6ah2Bv2mNDbCPty8/s320/Zip+tie+terminal+cables.jpg" width="156" /></a></div><div class="separator" style="clear: both; text-align: center;">I zip tied the adjacent wires so that it wont come off easily. </div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOktKvOveeS2aso5VETiZR7onodj-Ck9WRpbwFuVej7IcNIguRhavK6V2C96vFghdH1tj_t9S8nti5btzYVo2oxL-NOSZm5uFxqXSrrkVjn2b5qYw7i6ydrayQDEyd9hQTgtmY6UR3y9w/s2543/20210728_010513.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2543" data-original-width="1236" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOktKvOveeS2aso5VETiZR7onodj-Ck9WRpbwFuVej7IcNIguRhavK6V2C96vFghdH1tj_t9S8nti5btzYVo2oxL-NOSZm5uFxqXSrrkVjn2b5qYw7i6ydrayQDEyd9hQTgtmY6UR3y9w/s320/20210728_010513.jpg" width="156" /></a></div><div class="separator" style="clear: both; text-align: center;">Black remote turn on wire in the background. The rest are speaker wires with proper crimped terminals</div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEha4GQyQBo1k_Sc2dIB3fU94EXe_cPUuvLxDbkdRii5oEymiD5Uyordwv-3QD-Q9YhWeYLm4aUZfE4YC7hxfI1CmMIbAEmFVJI_ddKL8_sIfqyuzwmsArFyONfKHi2JR9VD3qRB_tXhIng/s2543/20210727_185250.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1236" data-original-width="2543" height="156" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEha4GQyQBo1k_Sc2dIB3fU94EXe_cPUuvLxDbkdRii5oEymiD5Uyordwv-3QD-Q9YhWeYLm4aUZfE4YC7hxfI1CmMIbAEmFVJI_ddKL8_sIfqyuzwmsArFyONfKHi2JR9VD3qRB_tXhIng/s320/20210727_185250.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;">This power cable is dangerous hence the added bellows for more protection</div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLkJikUth3rtUQn0E5_3wYE6BNdjTVBNd7UhsNRhkHfJak2TPRtHgedO8Zs9iylN_s3l0Ga0EUC5-rELoX1JZ0jcuwISW7mShQS4cZy-mnkeqfYHtqKOgXiqOMruY3HegCXa54jH89O3U/s2543/20210727_112856.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1236" data-original-width="2543" height="156" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLkJikUth3rtUQn0E5_3wYE6BNdjTVBNd7UhsNRhkHfJak2TPRtHgedO8Zs9iylN_s3l0Ga0EUC5-rELoX1JZ0jcuwISW7mShQS4cZy-mnkeqfYHtqKOgXiqOMruY3HegCXa54jH89O3U/s320/20210727_112856.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;">Multi strand speaker cable. Very high quality but no brand.</div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: left;">PUT IT ALTOGETHER </div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;">The front speakers are mounted using the plastic bracket that came with the purchase and they worked fine. All wires are neatly tucked under the carpet and arranged. </div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiu0vHD7f71joYLlihvO8AIfHiESWvYQzcl-0MeKiujvwP8cwW200YpqWVD3TbSLUzYOjtZTN-wd0UusxWuDyIzqpLI63PibsRSO4kZJBOYCvcxRIf5R2Uk3UDZ7e9yYKv6K3xbV76w-L8/s2543/LEFT+front.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1236" data-original-width="2543" height="156" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiu0vHD7f71joYLlihvO8AIfHiESWvYQzcl-0MeKiujvwP8cwW200YpqWVD3TbSLUzYOjtZTN-wd0UusxWuDyIzqpLI63PibsRSO4kZJBOYCvcxRIf5R2Uk3UDZ7e9yYKv6K3xbV76w-L8/s320/LEFT+front.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;">Front Left</div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8H4mkl2-wFLZUq2HZYxc8fYnN8BSNzMREb0lKiQ0XN228mZePcBfC1p1-nxAx786RFwNTIrGMpAHyl__3o-x4Ux6arKEoELiwXmWcGU9iDev2yLcQuiqtNNds2mP8o_BYtW5Q1NP4MMU/s2543/RIGHT+front.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1236" data-original-width="2543" height="156" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8H4mkl2-wFLZUq2HZYxc8fYnN8BSNzMREb0lKiQ0XN228mZePcBfC1p1-nxAx786RFwNTIrGMpAHyl__3o-x4Ux6arKEoELiwXmWcGU9iDev2yLcQuiqtNNds2mP8o_BYtW5Q1NP4MMU/s320/RIGHT+front.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;">Front Right</div><br /><div class="separator" style="clear: both; text-align: left;">FRONT SPEAKER BAFFLES </div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;">Water can sip through the window areas. You need this one so that front speakers will not have water damages. ABS 3D printed these and fits in exactly. ABS will withstand summer temperature and hold its shape.</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiP7oS5FgZb217JectbaliuOTSf4xylvXrFP6aYWVGix6ht4qjPejr-FdtKuTJ3pXW9Syv6x4A64_pnpqhL7qFq6VZ68NMcUiyIFbcWBsfETlNABy2MpC-bOUVKHwOXOXVSyij79tuMP10/s2543/20210722_111044.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1236" data-original-width="2543" height="156" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiP7oS5FgZb217JectbaliuOTSf4xylvXrFP6aYWVGix6ht4qjPejr-FdtKuTJ3pXW9Syv6x4A64_pnpqhL7qFq6VZ68NMcUiyIFbcWBsfETlNABy2MpC-bOUVKHwOXOXVSyij79tuMP10/s320/20210722_111044.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitJBpKqo-DpyO7HP7ai-KPu8xq2hexnniWWn4PHE1J3lGDfbW2G41ALebNu0D4bgL0UTjty8yf6vKlAexoWRkDewdDaXhX1RbK4A0YbybLZtttv3t0nf43edeyZIttFHjpwgS-8cz9pu8/s2543/20210722_111211.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1236" data-original-width="2543" height="156" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitJBpKqo-DpyO7HP7ai-KPu8xq2hexnniWWn4PHE1J3lGDfbW2G41ALebNu0D4bgL0UTjty8yf6vKlAexoWRkDewdDaXhX1RbK4A0YbybLZtttv3t0nf43edeyZIttFHjpwgS-8cz9pu8/s320/20210722_111211.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkAHBxyhZzEqqJlkaYNbJtOtBZQH9eYNnUux5ysoex1AIKBiWmzKaz435qM_SHEYqn97wNhYSul7xYrzMr9d_0KhidfybfDa6iQPDUu9CqUK2vIFei4vNrBnJZp98wimFiAuYpX2dmrMw/s2543/20210722_112317.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1236" data-original-width="2543" height="156" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkAHBxyhZzEqqJlkaYNbJtOtBZQH9eYNnUux5ysoex1AIKBiWmzKaz435qM_SHEYqn97wNhYSul7xYrzMr9d_0KhidfybfDa6iQPDUu9CqUK2vIFei4vNrBnJZp98wimFiAuYpX2dmrMw/s320/20210722_112317.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1YCruBIi0BEHQ9kuu1UGJpmJWFcs6VMs8iFeDmyzxYHJehd3E7yzp4RGWzwIRDlopGz1KdWeRPYppWpExrchwGidfjj2ySbBRIsFhjEDKeYIT0hMxYNgzq5r4AYSw3axc6ab9Zsu_5BY/s2543/Baffle+cover+front.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1236" data-original-width="2543" height="156" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1YCruBIi0BEHQ9kuu1UGJpmJWFcs6VMs8iFeDmyzxYHJehd3E7yzp4RGWzwIRDlopGz1KdWeRPYppWpExrchwGidfjj2ySbBRIsFhjEDKeYIT0hMxYNgzq5r4AYSw3axc6ab9Zsu_5BY/s320/Baffle+cover+front.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;">Front view of water baffle</div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfhTaJj2OkL0HdiQGWTuFo0IZyMPVCG_VK8QJDsMeIfiBD1tHREAp7KpZjRXU6j4-j5uuZ_J8srzmspUI-d1xEMFEN_Aty5JbepOUjWQpiRQYFyO_ALkTeWZ60XpkGosgF9S_IBO-pR24/s2543/Baffle+cover+side.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2543" data-original-width="1236" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfhTaJj2OkL0HdiQGWTuFo0IZyMPVCG_VK8QJDsMeIfiBD1tHREAp7KpZjRXU6j4-j5uuZ_J8srzmspUI-d1xEMFEN_Aty5JbepOUjWQpiRQYFyO_ALkTeWZ60XpkGosgF9S_IBO-pR24/s320/Baffle+cover+side.jpg" width="156" /></a></div><div class="separator" style="clear: both; text-align: center;">Side view of Water baffle </div><br /><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;">AMPLIFIER FLOATING MOUNT </div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;">Most installer will secure the Amp either behind the trunk or put it under the front passenger seat. Trunk space are precious and will need longer power cables and add up cost. Put it under the passenger seat means it might be kicked by rear passengers and also reduce leg room. The idle mount is a floating Amp. Brackets are made and bolted to the seat and the Amp mounted to this bracket. </div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_cSyYMX6wpdQfGDN_h8orkjBumJ77nOEuJjanPmpNdoKmlIWaNfoZcnhqrslLGZx37uuuKP0loJRY7stDK3dtw0QLWwiATS4OKvfmPp59mQyK8zR42SePFii4hYOHepzNX-Hvli7913k/s2543/20210606_180534.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1236" data-original-width="2543" height="156" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_cSyYMX6wpdQfGDN_h8orkjBumJ77nOEuJjanPmpNdoKmlIWaNfoZcnhqrslLGZx37uuuKP0loJRY7stDK3dtw0QLWwiATS4OKvfmPp59mQyK8zR42SePFii4hYOHepzNX-Hvli7913k/s320/20210606_180534.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;">Bracket and MDF board assembled </div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhEqUIgz2PeSWfCwCyUqF5bumHTIJGKeIzl6qs9ROIsp6qXH81uNr4MCveQXUAlXKHx9cHMxH95u09-Emf-F9RRiQjEuN1sfWAezF725-uAiMpKFK5zwjDvjxG8_KRAcsMW1-pamyDKXY/s2543/Floating+mount.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1236" data-original-width="2543" height="156" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhEqUIgz2PeSWfCwCyUqF5bumHTIJGKeIzl6qs9ROIsp6qXH81uNr4MCveQXUAlXKHx9cHMxH95u09-Emf-F9RRiQjEuN1sfWAezF725-uAiMpKFK5zwjDvjxG8_KRAcsMW1-pamyDKXY/s320/Floating+mount.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;">12mm MDF board used for strength and seperate chasis GND from Amp</div><div class="separator" style="clear: both; text-align: center;">Checked the chair sliding clearance when it moves forward and backwards</div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: left;">GROUND WIRE</div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;">This wire is anchored to the chair itself since its all metal underneath so doing it this way means rear passengers will not kick onto it.</div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjN-z9psZJjSKDeuNAux8r3FjhMdR8pm_UsaE8Jq9NFfIfrA_pInAvog-D9Lg0qhvpuVI3r27l9IB2S9D13tbKDSeqdfP06kZ03027rYDRJVuZcldpm7SuaRpjchUHYqS4_8QZxOuojbzI/s2543/20210728_002214.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1236" data-original-width="2543" height="156" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjN-z9psZJjSKDeuNAux8r3FjhMdR8pm_UsaE8Jq9NFfIfrA_pInAvog-D9Lg0qhvpuVI3r27l9IB2S9D13tbKDSeqdfP06kZ03027rYDRJVuZcldpm7SuaRpjchUHYqS4_8QZxOuojbzI/s320/20210728_002214.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: left;">The Ground wire for the Amp. Its a strong connection point</div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;">TWEETER SPEAKER </div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;">i dont like cutting the factory door interior panel to install the tweeters so i made a curved triangular box and it sits on the dashboard top. Easy.</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvgNc7QzgH81HXBnwiARPrdW1k3t_f7bQtj4SlQpolyl9qsF97tCUH7d7oFQKN3L2WP_Nrynt39inwXsFhyonl3-d6-rH3tytbEXgF4227-VkvJKjvRoy3O10ujuYelWAbEqWSCMGLL8o/s2543/20210517_134419.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1236" data-original-width="2543" height="156" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvgNc7QzgH81HXBnwiARPrdW1k3t_f7bQtj4SlQpolyl9qsF97tCUH7d7oFQKN3L2WP_Nrynt39inwXsFhyonl3-d6-rH3tytbEXgF4227-VkvJKjvRoy3O10ujuYelWAbEqWSCMGLL8o/s320/20210517_134419.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjAQ-mfdCXxd0X528MvTSiPqsr18eMFfjVJMh7eMm3pAtRgKdnhp0evOCA65f7zZf9VyUy1CohIwF4JBVYea45vsrIRZlBJJ7Gyp14WIvtmh12WiVH-TQw8BYpXMgPmknoSwiTv8GKRM0A/s2543/20210517_134627.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1236" data-original-width="2543" height="156" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjAQ-mfdCXxd0X528MvTSiPqsr18eMFfjVJMh7eMm3pAtRgKdnhp0evOCA65f7zZf9VyUy1CohIwF4JBVYea45vsrIRZlBJJ7Gyp14WIvtmh12WiVH-TQw8BYpXMgPmknoSwiTv8GKRM0A/s320/20210517_134627.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8j8fTeLHz27d62UkD7SsJ5BsmAQ1tYtVEP1HFP7rgRi6pJbI7XVMErMra-oNXCwATLan3oIkFivz8orhyphenhyphenCEtazMCsPBZGFH74e6m-U6KzFDGBYmGYtYd5xsT1KCYdAhpqHSpMCgJn5ME/s2543/20210517_134635.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1236" data-original-width="2543" height="156" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8j8fTeLHz27d62UkD7SsJ5BsmAQ1tYtVEP1HFP7rgRi6pJbI7XVMErMra-oNXCwATLan3oIkFivz8orhyphenhyphenCEtazMCsPBZGFH74e6m-U6KzFDGBYmGYtYd5xsT1KCYdAhpqHSpMCgJn5ME/s320/20210517_134635.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgscnPf1DZNdkipZWggD_B7wYoGJASI5eZ_kvbn1K1oslHnmqBaSF-_Yaedx9ckg1g5C9vgfVkG7MH3v7SY-nobHip2yzKKvYLdc1YDBkFfhcGIANhEctbVih4sQgx-zybjjdvee23uwpU/s2543/20210806_210647.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1236" data-original-width="2543" height="156" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgscnPf1DZNdkipZWggD_B7wYoGJASI5eZ_kvbn1K1oslHnmqBaSF-_Yaedx9ckg1g5C9vgfVkG7MH3v7SY-nobHip2yzKKvYLdc1YDBkFfhcGIANhEctbVih4sQgx-zybjjdvee23uwpU/s320/20210806_210647.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;">Add a badge and it looks awesome!</div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;">POWER UP </div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;">Connect all the wires to the amp and turn it on. The amp lights up and the music fills the interior. Sound imaging is great and seems to come directly at you in front of the car. Just amazing!</div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;">COMMON PROBLEMS</div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;">The trunk torsion bars are going to vibrate once the volume is cranked up. Simplest fix is to pack in between these bars with thick sponge and damp the annoying resonance.</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhyGsrNZYrTlwnZxD-gM-WD9A28qtmaeaAXtNkE3gGtMMl5IQYW4X0dDNYM4exm02nXIeXIu-c-ofV1B-_lEPMEZX7eteu-P2YwRPSG7GifS1xKa_G9Tbt1wrBgt_tU2Hq3qBmjgunp8g8/s2543/20210801_001554.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2543" data-original-width="1236" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhyGsrNZYrTlwnZxD-gM-WD9A28qtmaeaAXtNkE3gGtMMl5IQYW4X0dDNYM4exm02nXIeXIu-c-ofV1B-_lEPMEZX7eteu-P2YwRPSG7GifS1xKa_G9Tbt1wrBgt_tU2Hq3qBmjgunp8g8/s320/20210801_001554.jpg" width="156" /></a></div><div class="separator" style="clear: both; text-align: center;">Damping the torsion bar vibration</div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiupW2wrlc0bmiIsFd7fI3NPQP_mNJshbR8FVtRKAw1Q2seQGpoE-DmsPRwlhJsq4ek4rqz68rlwa6Jeg_yTFeaqeRPp93D3ItbJErjf73yjRS51T_GsH28pLCrgBJv7JalyE-B1C8tXcQ/s2543/20210801_001716.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1236" data-original-width="2543" height="156" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiupW2wrlc0bmiIsFd7fI3NPQP_mNJshbR8FVtRKAw1Q2seQGpoE-DmsPRwlhJsq4ek4rqz68rlwa6Jeg_yTFeaqeRPp93D3ItbJErjf73yjRS51T_GsH28pLCrgBJv7JalyE-B1C8tXcQ/s320/20210801_001716.jpg" width="320" /></a></div>Quality thick sponge<br /><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhGdSDRNRoiEoVKxIbXAdmUVZTFOtnSpK_sWMQf30vQxeGCmvwLE-PefGQ75xAhIjQ-kGClVbf4QD_u_AtvSrdpLIhdNdIAiFCHUYNSY3pcl4tSxjg-4Y70jSodkV6ttgTjzDFj0x2ugzM/s2543/20210801_001523.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1236" data-original-width="2543" height="156" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhGdSDRNRoiEoVKxIbXAdmUVZTFOtnSpK_sWMQf30vQxeGCmvwLE-PefGQ75xAhIjQ-kGClVbf4QD_u_AtvSrdpLIhdNdIAiFCHUYNSY3pcl4tSxjg-4Y70jSodkV6ttgTjzDFj0x2ugzM/s320/20210801_001523.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;">Waterproof rubber baffles for the rear speakers and the thick sponge to dampen the vibrations</div> </div><div><br /></div><div>CONCLUSION</div><div><br /></div><div>This DIY project is not for the faint hearted. It involves a lot of foresight and identifying problems. If you are not comfortable doing this yourself, pay someone to do it before you damage the vehicle as it involves a lot of wiring and dismantling of cosmetic panels.<br /><div class="separator" style="clear: both; text-align: left;"><br /></div><br /></div><div class="separator" style="clear: both; text-align: center;"><br /></div><br /><div class="separator" style="clear: both; text-align: center;"><br /></div><br /></div>Flybywire http://www.blogger.com/profile/12033050948969565462noreply@blogger.com0tag:blogger.com,1999:blog-4428828201756422934.post-36592931328305083842020-04-12T07:44:00.001+08:002020-04-12T07:44:55.041+08:00DREMEL drill press Gear makingI keep a lot of junk because of missing parts and sometimes I just don't feel like disposing it. One of these items happened to be a DREMEL Multiprocessor DELUXE DRILL MODEL 212. It's not so deluxe after the pinion and rack system broke.<br />
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When I inspected the problem, the culprit was a plastic gear. No parts were available for replacement ( obvious reason being $ minded Dremel wanted to make more money from newer models). It was bubbled wrapped and kept in the storeroom for nearly 2 decades and was slowly forgotten until recently.<br />
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I decided to repair it, not that I needed it badly, and to challenge myself to do something that I have never done it. It was no easy task. There was little information about gear making and I am not in this industry or a metal fabricator. As far as I know, production gears are made from cold forging techniques. They have dies with the opposite shapes and a whopping 200 tons of pressure is applied to a billet of softer material into the die . A bit like making jelly in a mould but instead if pourIng molten metal into a mould, excessive pressure is used. Examples are Shimano crown gears in fishing reels using this type of cold forging process. But who am I kidding, DIY project using 200 tons of force!</div>
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So the only way to make a replacement gear is the use of a gear cutter. I need just one gear and it's a one off thing.</div>
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From the broken gear, measurements were made, number of teeth were interpolated into the imaginary calculations. These were not difficult being a science student in my teenage days, I can still remember geometry and properties of circles very well. It worked out that the gear had 16 tooth and it's pitch was determined from the straight rack by way of vernier measuring. Believe me it took me many weeks to accurately determine the pitch of the gear. If the wrong diametrial pitch was taken, the resulting gear will never mesh properly. There are also many types of gears and the one I was working on is an involute gear. So call involute because the curves on the gears are part of an involute circle. Very confusing when I first started understanding this, but the more I read, the more interesting it got.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEir-Tv5PPHJHTgGkdwpDZSZjsHdjYIV6EssyyXNv_skN30oP3t6Mp7MEl1TcBv7hAs9d-MpiH2tG1PQv-41T8bZnI6nYJfOQs63b2t3zuOlru3T6_MbM1BFG9OBUinJXYiwiTQdgyeG_zM/s1600/Remnants+of+a+plastic+gear.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEir-Tv5PPHJHTgGkdwpDZSZjsHdjYIV6EssyyXNv_skN30oP3t6Mp7MEl1TcBv7hAs9d-MpiH2tG1PQv-41T8bZnI6nYJfOQs63b2t3zuOlru3T6_MbM1BFG9OBUinJXYiwiTQdgyeG_zM/s320/Remnants+of+a+plastic+gear.jpg" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_tX8p2P6bHAyto2gvjnob9g9gjtP2wTYkhydEiTs_-xXbHS2ttIxngKKX4_flVksOLzUUU9mXRkUOQk7OhYpZYq9VSd_W_YY2Fk_9az-JaF9ed67R4Whgh4PNGFvz2QEkV0KJ2UQB29s/s1600/Remnants+of+a+plastic+gear+II.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_tX8p2P6bHAyto2gvjnob9g9gjtP2wTYkhydEiTs_-xXbHS2ttIxngKKX4_flVksOLzUUU9mXRkUOQk7OhYpZYq9VSd_W_YY2Fk_9az-JaF9ed67R4Whgh4PNGFvz2QEkV0KJ2UQB29s/s320/Remnants+of+a+plastic+gear+II.jpg" width="320" /></a></div>
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The easiest way to make this gear replacement is using an involute gear cutter. Gear hobbIng is also possible but ........</div>
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So making a gear is actually removing material from a complete round rod to form the tooth of the gears, so technically it's not gear cutting but that's what they call it anyway. Like why they call a skyscraper building when it's already completed ? Anyway I know to cut 16 tooth means I need to rotate the blank rod 22.5 degrees precisely for each pass, otherwise the finished product looks odd and of course it won't mesh with the straight rack. </div>
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7075 aluminium was chosen . If I were to do this again, I would select 60xx aluminium. 7075 being a harder Alu alloy it's was so damn hard to cut it. Next time stick with something that's not an overkill. </div>
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16 passes were made and the resulting gear was amazing. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimaCBBfHGkTXVyPy8Xxl02r2Hu6CaVADZ1Li9fy9_pe0dsMJz7pQZBEE5JaFjIvNWDj_G4Bcb-A4nWIu7Mtmnoj9bE3rXFuQpF-rSBnP2YXIZk0D4wozRhaMtkO5GY_kj4v3hNdKP0_rY/s1600/20191121_082142.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimaCBBfHGkTXVyPy8Xxl02r2Hu6CaVADZ1Li9fy9_pe0dsMJz7pQZBEE5JaFjIvNWDj_G4Bcb-A4nWIu7Mtmnoj9bE3rXFuQpF-rSBnP2YXIZk0D4wozRhaMtkO5GY_kj4v3hNdKP0_rY/s320/20191121_082142.jpg" width="320" /></a></div>
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There was a problem, I made the cut too deep so the mesh was sloppy. So second one was made ( I too have my fair share of failures ) and I cut it shallower. And there's a formula to follow when cutting the depth of gears . Lesson learnt.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLbqQ4akQ0l5CxvHcxOuXmcGY9nmWXUW1xh3Zoz4RdAWcmpNwZ53AfeAqf4A3ZFqxPSSZ8sQb9pVzuFmqnMsGUwGpCA6w8TFZT_rFWZcrGYLpa5BC_ASWM9CqwcG_U3VRXvXEBmbtxni8/s1600/20191124_111938.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLbqQ4akQ0l5CxvHcxOuXmcGY9nmWXUW1xh3Zoz4RdAWcmpNwZ53AfeAqf4A3ZFqxPSSZ8sQb9pVzuFmqnMsGUwGpCA6w8TFZT_rFWZcrGYLpa5BC_ASWM9CqwcG_U3VRXvXEBmbtxni8/s320/20191124_111938.jpg" width="320" /></a></div>
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The second gear made was much better and I move on to solve the rotating stem that must be attached to the gear. Dremel used a positive type of engaging mechanism. It's too complicated to replicate on the aluminium it has a shape much like a Mercedes Benz logo. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmvnboKcQSujrORqiGpHH4KLszGoayzJTThr2CCyraRa37-tIlAwOnSslGHLQwFJMfmHPdZT5eqrNzReaFhXmRix4d7R4Tu06exj5m-bXOLNiMlVNf4cfAmbCluOlKer93uSsTr4qJK8I/s1600/20191202_180246.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmvnboKcQSujrORqiGpHH4KLszGoayzJTThr2CCyraRa37-tIlAwOnSslGHLQwFJMfmHPdZT5eqrNzReaFhXmRix4d7R4Tu06exj5m-bXOLNiMlVNf4cfAmbCluOlKer93uSsTr4qJK8I/s320/20191202_180246.jpg" width="320" /></a></div>
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I went for an easier approach . Just epoxy the gear and the rotating stem assembly. I made a tight fit recess to receive the stem so that it would not be sloppy and I was wrong. Later I learnt that a bit of slop would assist in the epoxy stage.</div>
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Because the stem and the gear are two seperate pieces, to find a common center is difficult. So the recess part of the gear was made slightly bigger for adjustment just before the epoxy sets.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0hOZReljpsynhIpUMAM7E_OMI7WoS6_g5oHzoowIi-tTxdO80Ulv-KI0v-UZ0O28HXm6n3-TYiGSCp752K0U4ZYa-OllQjxTkVd1pOfKywsjlVVyMWEb4v_4Sc_a570N6vHWcF6evRFc/s1600/Making+a+0.5mm+slit.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0hOZReljpsynhIpUMAM7E_OMI7WoS6_g5oHzoowIi-tTxdO80Ulv-KI0v-UZ0O28HXm6n3-TYiGSCp752K0U4ZYa-OllQjxTkVd1pOfKywsjlVVyMWEb4v_4Sc_a570N6vHWcF6evRFc/s320/Making+a+0.5mm+slit.jpg" width="320" /></a></div>
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Before epoxy, I cut a 0.5,mm slot so that the return coil spring can be attached. This slot must be made exactly across the diameter otherwise the rotating gear will be off center and it will bind</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEx6G8wVI8njYeZgtgeUQfYJwrTrlhGO-9Os_jw401xme7uGE6e7Fl1XPfQFQOBKPfKUIl8sH3z8dHfu3bXPAAkJRGBkuMAPDRENN4F_2qgyr2N-3ZhJQ57Skq8sxDpxJYZq5rK9H0zEQ/s1600/20191205_234932.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEx6G8wVI8njYeZgtgeUQfYJwrTrlhGO-9Os_jw401xme7uGE6e7Fl1XPfQFQOBKPfKUIl8sH3z8dHfu3bXPAAkJRGBkuMAPDRENN4F_2qgyr2N-3ZhJQ57Skq8sxDpxJYZq5rK9H0zEQ/s320/20191205_234932.jpg" width="320" /></a></div>
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With that done, the gear is mounted on the lathe and dial in to get the best possible runout of 0.10mm, zero is ideal. The stem was well made by Dremel and had a 0mm runout. </div>
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The stem was mounted onto the tail stock and epoxy (JB weld) applied and the 2 pieces are bonded together. Best possible bond is to have no air gap.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgb1L4HJ_IxW51NceupUjKDWH5hd1saUCPPurq5Wy4jNaIYNytgUK1OGidLPE4f_4eZFrJf4dMT1FFv_EOODuDpj5Jf165yWNQQ4KEuv8CckZ08Bd2aSY-RV0h6JK9YXQ_Z_RqVpcSHOwo/s1600/20191203_224532.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgb1L4HJ_IxW51NceupUjKDWH5hd1saUCPPurq5Wy4jNaIYNytgUK1OGidLPE4f_4eZFrJf4dMT1FFv_EOODuDpj5Jf165yWNQQ4KEuv8CckZ08Bd2aSY-RV0h6JK9YXQ_Z_RqVpcSHOwo/s320/20191203_224532.jpg" width="320" /></a></div>
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The next 6 hrs was checking for runout just before the epoxy sets after which no adjustments can be made.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigCGl0HsqnplgkShhz2s9qPXrkCFiwHemEo1sYe5Ek4y7RUwsI3Lv_ahHKBUN5arnBa2SrD0N09pxQjRCRedbRuCdZSgbasPJcx4LpkeZGOXor1JtWhcBHVwllorHRlOyQijDHmoDFpts/s1600/Epoxy+bonding+runout+check.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1000" data-original-width="1600" height="200" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigCGl0HsqnplgkShhz2s9qPXrkCFiwHemEo1sYe5Ek4y7RUwsI3Lv_ahHKBUN5arnBa2SrD0N09pxQjRCRedbRuCdZSgbasPJcx4LpkeZGOXor1JtWhcBHVwllorHRlOyQijDHmoDFpts/s320/Epoxy+bonding+runout+check.jpg" width="320" /></a></div>
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After 24 hrs, the epoxy sets and the part is ready for assembly. Aluminium bushing was turned out to better support the stem during use so that the stress distributed on the bush. Later I made Delrin bush to replace the aluminium one. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiBU4fHihuDaywXgvFaU0RRy7Fes8WbsbpNEJSLqNvpc1zo3TIT9waFR4IDRK353kRS1wOe4AFfXCtWF6QsbEkz5H3Yauf8IE5CuxqLhN1UiiqVlsi7_2gW2jcvv-ZykUK0XcpIbqpZq6s/s1600/20191205_234650.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiBU4fHihuDaywXgvFaU0RRy7Fes8WbsbpNEJSLqNvpc1zo3TIT9waFR4IDRK353kRS1wOe4AFfXCtWF6QsbEkz5H3Yauf8IE5CuxqLhN1UiiqVlsi7_2gW2jcvv-ZykUK0XcpIbqpZq6s/s320/20191205_234650.jpg" width="320" /></a></div>
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And with the parts made, just assemble it together and use the press.</div>
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<span id="goog_2071236541"></span><span id="goog_2071236542"></span> There was still some binding between the gear and the rack so I used engjneer's dye to locate the binding and removed some more material from the gear. And that little bit of material removed made a huge difference.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcpt3TL42IL_lOhr-wIQD0gjha6w0zktsqCWix8SIHTFY_u5bcPLc5SLq1GptlewDiQ6jNM90I2_21L-T7exCCu2nGYtV3p7FVvWv9gMrOkWPpQX13_EYsOW57pnji6__P55SoQ1PEYpc/s1600/20191204_220132.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcpt3TL42IL_lOhr-wIQD0gjha6w0zktsqCWix8SIHTFY_u5bcPLc5SLq1GptlewDiQ6jNM90I2_21L-T7exCCu2nGYtV3p7FVvWv9gMrOkWPpQX13_EYsOW57pnji6__P55SoQ1PEYpc/s320/20191204_220132.jpg" width="320" /></a></div>
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The final and finished product.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSBHgBinUlH40c8xKCMxg6pIk2GoMedZvZKJPIM_y0dpObwtVYTLxmsO79Ah7wLpkYhS2yF4r1w0YshKwpwD5KXteBVLlGKjxmeuFCTPoThFPQTUU5I23W6kQ0SOkvM9bXazztYdvakac/s1600/Fully+restored+drill+press.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="900" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSBHgBinUlH40c8xKCMxg6pIk2GoMedZvZKJPIM_y0dpObwtVYTLxmsO79Ah7wLpkYhS2yF4r1w0YshKwpwD5KXteBVLlGKjxmeuFCTPoThFPQTUU5I23W6kQ0SOkvM9bXazztYdvakac/s320/Fully+restored+drill+press.jpg" width="180" /></a></div>
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It was a good learning experience making this part. A lot of thinking was involved.</div>
Flybywire http://www.blogger.com/profile/12033050948969565462noreply@blogger.com0tag:blogger.com,1999:blog-4428828201756422934.post-91480933312112752022020-02-26T06:53:00.001+08:002020-02-26T06:53:22.912+08:00Timing belt, water pump and crank seal replacement<div style="text-align: justify;">
I had some free time and decided it was time to replace some vital parts of a vehicle that I bought second hand. These parts clocked the 100,000km mark so it's due for replacement. I have replaced these items before on some other vehicle make but I must say that Japanese cars are much easier as compared to continental cars.<br />
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Before you start, it's a good ideal to have zip loc bags ready to keep and label all the bolts removed. It will save you lots of time when putting back everything. Ask me how I know.<br />
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Your car may be different from the description below but it will not be significant. Refer to your service manual. You need one weekend to do this job, long weekend is prefered. I did this almost 1 year ago so some steps described may not be in the order done.<br />
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Prepare all the tools required.<br />
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Abbreviation used TB -timing belt, WP -water pump<br />
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First park the car on level ground and support the vehicle on car jacks. Choke the rear wheels and apply the hand brakes. Disconnect the battery terminals. <br />
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Remove the alternator and aircon belts. Loosen all the spark plugs<br />
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Dismantle the valve cover, protect the overhead cams with a clean towel.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjtJhvXQi8vRc75MtxWOvGIbY58Xj8cvTP1Q7QPNAe2GHx_Cw_2H7HSfHO7T6hmz5udPY3x4ZT52-k9yt6Y2ImAsBuHjGKXEYxYjc5d3SIZLVBsb3UooCHLN5O-ucCYh66MyfmX8vMBsME/s1600/20190202_075615.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjtJhvXQi8vRc75MtxWOvGIbY58Xj8cvTP1Q7QPNAe2GHx_Cw_2H7HSfHO7T6hmz5udPY3x4ZT52-k9yt6Y2ImAsBuHjGKXEYxYjc5d3SIZLVBsb3UooCHLN5O-ucCYh66MyfmX8vMBsME/s320/20190202_075615.jpg" width="320" /></a></div>
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Undo the 3 bolts that attachs the pulley to the water pump. Remove the TB plastic covers that protects the TB from contamination. The picture below shows the first half is removed and the lower half needs to be removed as well. There are usually 9 bolts that hold the 2 pieces of TB covers to the engine housing.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh7Fph4lF_9o53GIyBS3R7eFpdVeZxHMtOsbCeP4K1QDGkDO1OP0YOK-rg49bhB_IKHtcRKwBUSdIlfNUFyMI8UK7AS0e7QcIjbVjDlZ6TDbrW_Ez_Qnnc3OW5mTUQE1hDKJbZHa71KHF0/s1600/TB+cover+top+half+removed.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh7Fph4lF_9o53GIyBS3R7eFpdVeZxHMtOsbCeP4K1QDGkDO1OP0YOK-rg49bhB_IKHtcRKwBUSdIlfNUFyMI8UK7AS0e7QcIjbVjDlZ6TDbrW_Ez_Qnnc3OW5mTUQE1hDKJbZHa71KHF0/s320/TB+cover+top+half+removed.jpg" width="320" /></a></div>
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With the lower half of the TB plastic cover removed, the full glory of the TB can be seen.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjt9XDmOecvfnHu2StQ06AJE-ivn5vHw_VvqupFIGzpSihMFoAzZ3T2Fg7J2PIDmw-5l2h27jS5ywT7jX4vmj4ivzabaUYLa-9PoBRX3gGaHijqhvqPZAHvjjBU1SqRePTiyirbN3c-7vw/s1600/TB+cover+lower+half+removed.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="900" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjt9XDmOecvfnHu2StQ06AJE-ivn5vHw_VvqupFIGzpSihMFoAzZ3T2Fg7J2PIDmw-5l2h27jS5ywT7jX4vmj4ivzabaUYLa-9PoBRX3gGaHijqhvqPZAHvjjBU1SqRePTiyirbN3c-7vw/s320/TB+cover+lower+half+removed.jpg" width="180" /></a></div>
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Next remove the crank shaft pulley center bolt. This one is super tight. Service manual recommends the use of a special tool to tackle this . There is another method. The electric starter itself is a powerful enough to undo the bolt. Arrange the breaker bar to bear against the drive shaft .When the engine is cranked, the bolt does not rotate and is loosen. This step requires the gear box to be in the neutral position otherwise something bad will happen. Reconnect battery terminals to use the starter and undo the terminals when done.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNablXTJAh-witUBlviln_6mRAyqh7GDiFC7616prJINkrQDah5LCPVbIbMBXoZ6tkORF7nWf_8p6l3AFIAO-iyq_7m6_G8JYJ98L7tTCbHEZfuQcKjRDiq64KyZbIbJiULVPsOdKsE6k/s1600/20190202_083059.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNablXTJAh-witUBlviln_6mRAyqh7GDiFC7616prJINkrQDah5LCPVbIbMBXoZ6tkORF7nWf_8p6l3AFIAO-iyq_7m6_G8JYJ98L7tTCbHEZfuQcKjRDiq64KyZbIbJiULVPsOdKsE6k/s320/20190202_083059.jpg" width="320" /></a></div>
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Remove the crank shaft pulley to expose the crankshaft sprocket. The sprocket is a small toothed wheel that connects the TB. A woodruff key can be seen in the picture. Removing this key will loosen the crankshaft sprocket and expose a seal that needs to be changed.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7_wYci2jIxYVZ8uwCLpLobcF5g6n53miPWDe0YAGnQNmaeZPXPYrq4gqix_ULTqTAis1KhcaGTzJuXpjZZzbPcTQEGhr2mch6Qa4q0n_30qfRZlSmTlyczVX7wlwn30mBacJTP4Cmtx0/s1600/20190202_083526.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7_wYci2jIxYVZ8uwCLpLobcF5g6n53miPWDe0YAGnQNmaeZPXPYrq4gqix_ULTqTAis1KhcaGTzJuXpjZZzbPcTQEGhr2mch6Qa4q0n_30qfRZlSmTlyczVX7wlwn30mBacJTP4Cmtx0/s320/20190202_083526.jpg" width="320" /></a></div>
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Support the weight of the engine with a car jack and remove the right
hand engine mount and bracket. The bracket gets in the way to remove the
water pump . The bolts to the bracket are tight so use a cheater bar
for leverage again. </div>
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I normally mark the position of the belt and pulleys with colored marker so that assembly will be a breeze. This method has proven to be the best as compared to aligning the embossed arrows on the 3 pulley wheels at TDC ( top dead center) . Get to the crank shaft pulley (temporary assemble back the pulley with the same bolt) and turn this pulley clockwise until the engine is at TDC. When the engine is rotated clockwise to the TDC, mark with colored marker the position of the timing belt relative to the 3 pulleys. the pulleys and TC are clearly marked with different color to prevent mistakes. The factiry has marking on the exhaust and intake sprocket to show when the engine is at TDC. usually the two arrows will pointing towards one another.</div>
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On the bottom left is the tensioner bearing, it keeps the belt tension
in place and this needs to be replaced. The right hand side is also another bearing that needs to be replaced. Usually the timing belt kit
comes with all these parts. The belt goes around the intake and exhaust sprocket and also around at the bottom of the crank shaft sprocket.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZnaZM8v7dn7pecQMx8BHXuNBeEBs-43UirYKHFxGSP7d61ubjWfQ9XQ5A0PFmxVVi029hIlZqg1yUD-X3A5qUgEV0iv3j-sRvm7dde2i4uLI-HY-NC8torvnOpdMM5CqNA0qTdfb4HYU/s1600/Timing+cover+removed.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZnaZM8v7dn7pecQMx8BHXuNBeEBs-43UirYKHFxGSP7d61ubjWfQ9XQ5A0PFmxVVi029hIlZqg1yUD-X3A5qUgEV0iv3j-sRvm7dde2i4uLI-HY-NC8torvnOpdMM5CqNA0qTdfb4HYU/s320/Timing+cover+removed.jpg" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2vPV3G1Oi35fnLooybhG76uYOdEXY_Ey6Quf3E5oa1hZTyNTjzoZd4K1r2zwJKW4FqVEnIBzRs0p8w16hNLqpnDxm3vvrKSOlYrG86StKDJqpEM79SaTCngi_ngdj7GXyvIPzjBh3mjU/s1600/CRANKSHAFT+sensor+bracket+bolted+timing+cover.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2vPV3G1Oi35fnLooybhG76uYOdEXY_Ey6Quf3E5oa1hZTyNTjzoZd4K1r2zwJKW4FqVEnIBzRs0p8w16hNLqpnDxm3vvrKSOlYrG86StKDJqpEM79SaTCngi_ngdj7GXyvIPzjBh3mjU/s320/CRANKSHAFT+sensor+bracket+bolted+timing+cover.jpg" width="320" /></a></div>
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Unhook the spring that is attached to the tensioner bearing and undo the center bolt to loosen the bearing. Now move the bearing away from the belt. The belt can now be removed with ease.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhf8j3SLtTqWuE-Ddg9IgVJGz-3dSoDCCcpCMyuWNL7Ir9_HVony1ji69xYU59wGYbq8z2OBzYwou4k8reNpX7dzj2rW_5XMOfrwUgGDelOG-Ape29CZ2_WPGKB1sXZFzCNtECQBp8oQUo/s1600/20190202_110149.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhf8j3SLtTqWuE-Ddg9IgVJGz-3dSoDCCcpCMyuWNL7Ir9_HVony1ji69xYU59wGYbq8z2OBzYwou4k8reNpX7dzj2rW_5XMOfrwUgGDelOG-Ape29CZ2_WPGKB1sXZFzCNtECQBp8oQUo/s320/20190202_110149.jpg" width="320" /></a></div>
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The bottom picture shows both bearings and belt removed. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8_zWm3nt2g6BS0Y2f0iMvqIZlunRyQaRYUVee6r_uDwj1LTsLOpRKYFK6TKPQ1j8d1GK-TLBpo-ntcPHMlGUxio5jpEYrgjjmnhG_n9v35TtidKuZWDecyNMKuey9IBoMCRZDqxULP4Q/s1600/20190202_183041.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8_zWm3nt2g6BS0Y2f0iMvqIZlunRyQaRYUVee6r_uDwj1LTsLOpRKYFK6TKPQ1j8d1GK-TLBpo-ntcPHMlGUxio5jpEYrgjjmnhG_n9v35TtidKuZWDecyNMKuey9IBoMCRZDqxULP4Q/s320/20190202_183041.jpg" width="320" /></a></div>
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Get to the bottom of the car and remove the wooduff key and remove the crankshaft sprocket. You will be able to see a rubber seal . This is the crankshaft seal that seals the engine oil and needs to be replaced. I made a special tool to extract this piece of seal . Its very tight but care must be exercised not to marr or scratch the journal of the crankshaft. If its damaged, the crankshaft will have to be replaced. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjeO_-S4cWOqcxYsQF5Sg2-xVnmeAkQ0Vr1f4T8Q6AAeNX3Z4BH00MvELNMueR3zVQVVaLFUZdYwKrX8bAjbjRjEf_7S-n-wqLKop-_sNgjUD_uGQfaFalIfTG19zcbwL-fkqj3X4VhC_E/s1600/20190202_130737.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjeO_-S4cWOqcxYsQF5Sg2-xVnmeAkQ0Vr1f4T8Q6AAeNX3Z4BH00MvELNMueR3zVQVVaLFUZdYwKrX8bAjbjRjEf_7S-n-wqLKop-_sNgjUD_uGQfaFalIfTG19zcbwL-fkqj3X4VhC_E/s320/20190202_130737.jpg" width="320" /></a></div>
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Special tool in use. The triangle shape is part of the timing belt marking. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEju9hLUpkIjbk9ykXGTez5AndhAe9VLdXlTVCyvasV8aXVtczPK5-JqnCr-X7dHV3sRoCquhbvOO1dzrTsFGe3Tb4XTBALCTUu0D74NeX51_IRsawBoZ3ses_X9tYsWx1GPZDzgaOVVILU/s1600/20190202_142217.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEju9hLUpkIjbk9ykXGTez5AndhAe9VLdXlTVCyvasV8aXVtczPK5-JqnCr-X7dHV3sRoCquhbvOO1dzrTsFGe3Tb4XTBALCTUu0D74NeX51_IRsawBoZ3ses_X9tYsWx1GPZDzgaOVVILU/s320/20190202_142217.jpg" width="320" /></a></div>
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The seal is removed and journal inspected for deep scratches.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXb57SVoZFElAzJg-umPFny3Jip8XpWj67um21wtwCXF3ZZ7htAIE-NZqOqSdRA8qFniyH_zGY8g8muynqlwHHilwxhtZSsN8o-HO6qd70SHH9SRUqsTnJn8UoGMIkDo_iz9PHvKKtWLI/s1600/20190202_142723.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="900" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXb57SVoZFElAzJg-umPFny3Jip8XpWj67um21wtwCXF3ZZ7htAIE-NZqOqSdRA8qFniyH_zGY8g8muynqlwHHilwxhtZSsN8o-HO6qd70SHH9SRUqsTnJn8UoGMIkDo_iz9PHvKKtWLI/s320/20190202_142723.jpg" width="180" /></a></div>
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Replace with a new seal. Use the grease provided in the kit to ease the seal into its place. Tap it in squarely with a socket of a correct size diameter PVC pipe</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDM_uhOlr05PUzWJyNyKd1Iqj2TtQwurGGgOvZ6gPo-hSpGPeSZN94SgIdxC0LPmftvVi7_rThesIgSFjDXll04T9ksrSc1kiRAWg5l5ySs-KpDOmhsPJtoZH8KItzfYX3BBREtPUHKfw/s1600/20190202_164610.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDM_uhOlr05PUzWJyNyKd1Iqj2TtQwurGGgOvZ6gPo-hSpGPeSZN94SgIdxC0LPmftvVi7_rThesIgSFjDXll04T9ksrSc1kiRAWg5l5ySs-KpDOmhsPJtoZH8KItzfYX3BBREtPUHKfw/s320/20190202_164610.jpg" width="320" /></a></div>
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Remove the intake and exhaust sprocket and replace the seals as well. Two open enders are used to lock the cams in place to remove these two sprocket. the cams have a key way to accept the tools for lock down. Care must be taken not to damage the journal of the camshaft otherwise these have to be replaced. A note about the camshaft seals, they tight and removal might need a bit of struggle and swearing. Fitting in the new seals is exactly the same as the crankshaft seals</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimdfTzGDmw56QH2Id8yuPoGiIHstCNM-bdRAAsLdEM-VfDjiPcVHei-mlwl_RkZPl3nRg0b3_u6n6is9htTfhrLHZsdTLDjjN21aZOh0f_76WnG7bOE41yAdMyEk5f7mD9bQ5YJYPPrUw/s1600/20190203_102039.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="900" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimdfTzGDmw56QH2Id8yuPoGiIHstCNM-bdRAAsLdEM-VfDjiPcVHei-mlwl_RkZPl3nRg0b3_u6n6is9htTfhrLHZsdTLDjjN21aZOh0f_76WnG7bOE41yAdMyEk5f7mD9bQ5YJYPPrUw/s320/20190203_102039.jpg" width="180" /></a></div>
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Right side replaced. Left side has no seal and awaiting for replacement.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcB05kMA3teF9XuGYupQqWJlrWiolcMpMyoM9PqfQSa9AqU1jhr6B5x9tHKqwwTkX_UKAM6AdjNlQ7vUGLkSXskapBoDSgi3atQ87UZIj0K2rGxvDwsJJNbXMOTMCKDk-HkSSPpjV6fmY/s1600/20190203_155142.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcB05kMA3teF9XuGYupQqWJlrWiolcMpMyoM9PqfQSa9AqU1jhr6B5x9tHKqwwTkX_UKAM6AdjNlQ7vUGLkSXskapBoDSgi3atQ87UZIj0K2rGxvDwsJJNbXMOTMCKDk-HkSSPpjV6fmY/s320/20190203_155142.jpg" width="320" /></a></div>
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Install the two sprocket back and torqued down to service manual specification.</div>
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Now drain the radiator of all its fluid and store it in a container. Dispose the fluid responsibly. Place a note on the steering saying" Top Up radiator fluid before starting engine.</div>
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Locate a black O ring ( shown below) that needs to be replaced in the metal radiator hose that is part of the radiator hose. I had to to loosen the air con bracket that holds the air con compressor in place to access this O ring. </div>
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Replace all radiator rubber hoses if there are signs of worn out. Undo the bolts that secure the water pump and pull out the mechanical pump. More radiator fluid will flow out and get ready to catch them under the car.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhj9puvWbT68hFplwanrXtuVldYSSrmzHkjiKwNQhUrkf9MiPqF4g2XOQzMeXY16lH5GKPf3hovpRkDCPT2LG9EFUHuLGpgpKrv0pe5FM95hPE31it5McjxIKcjnHQOEvsrboPh0lGQP-o/s1600/20190202_170647.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="900" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhj9puvWbT68hFplwanrXtuVldYSSrmzHkjiKwNQhUrkf9MiPqF4g2XOQzMeXY16lH5GKPf3hovpRkDCPT2LG9EFUHuLGpgpKrv0pe5FM95hPE31it5McjxIKcjnHQOEvsrboPh0lGQP-o/s320/20190202_170647.jpg" width="180" /></a></div>
The old radiator gasket is probably stuck and needs to be removed by using a sharp razor blade. Use fine grit sand paper to remove any remaining stubborn gasket.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkps4xbwAokYpqfDIqI8XhPosJIFSw57fJEHsv7GDkR-lNjRW_-njWYshcCXJtGYC5E8lyx2lvr7KTUPAQZ-dpqtBgIo1Jpemj05Ul8ul2iVsSx8sEKxxYKqFyymdbLl1KpCbnXZSKEbA/s1600/Gasket+Stuck.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkps4xbwAokYpqfDIqI8XhPosJIFSw57fJEHsv7GDkR-lNjRW_-njWYshcCXJtGYC5E8lyx2lvr7KTUPAQZ-dpqtBgIo1Jpemj05Ul8ul2iVsSx8sEKxxYKqFyymdbLl1KpCbnXZSKEbA/s320/Gasket+Stuck.jpg" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXOC_DrrfbjaPv5EqGdqiqPPuVCJmUNgWAINqIrrmbe0cYSbg27nEDChyphenhyphenVAoTFyquUSCJ2Kq2HBjkJ7dUlrWRwnl7BsyrQBy-Ud2YUIcGb7oRpHxSd50GbgVvtT83_neXVTZQCV5FT9Cc/s1600/Gasket+removed.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXOC_DrrfbjaPv5EqGdqiqPPuVCJmUNgWAINqIrrmbe0cYSbg27nEDChyphenhyphenVAoTFyquUSCJ2Kq2HBjkJ7dUlrWRwnl7BsyrQBy-Ud2YUIcGb7oRpHxSd50GbgVvtT83_neXVTZQCV5FT9Cc/s320/Gasket+removed.jpg" width="320" /></a></div>
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Before installing the new pump, compare the new pump with the old one and see any significant difference. Once satisfied, use Permatex Aviation Form A gasket sealant liquid to adhere the gasket to the the pump. I do not like to use sillicon gasket , these sillicon will give lots of issues later including clogging the cooling system. </div>
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Apply the permatex sealant on both sides of the gasket and install the water pump. Torque down the bolts to specification.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiw0fA8t_kkAaYpxKk117XKdiAAKYDg8BdUF34WfgfWVih4TGBOVrCVHaRAcdCVw6qzv3m35v963d7AXMcaDcOq43IkZJFjgrrFuY7CypsumJG1OGlpLEYy2hp1SykmGw5GL561n3oCeD4/s1600/New+WP+with+gasket+on.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiw0fA8t_kkAaYpxKk117XKdiAAKYDg8BdUF34WfgfWVih4TGBOVrCVHaRAcdCVw6qzv3m35v963d7AXMcaDcOq43IkZJFjgrrFuY7CypsumJG1OGlpLEYy2hp1SykmGw5GL561n3oCeD4/s320/New+WP+with+gasket+on.jpg" width="320" /></a></div>
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Transfer the color marking done on the old TB to the new one. Install the new TB and align the colors marking of the TB to the color markings on the 3 sprockets made earlier.</div>
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Install the TB and it's two bearings. Hook the idle bearing spring in place and push the bearing against the TB slightly and tighten the bearing bolt to specification. Tighten the other TB bearing bolt to specification.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJh2M_6hmuo9sdKujqoTgeRvyQUSRxSBukfMN7DR76567aniy73TtBFz-u2k1KQS_A2SLyWatjfoJWaArb2mgjCgeRm4wxNvzjKNovFoXVMPU8sQTNEg1FY1rTi8-BiAwVIReWnWIlnjg/s1600/New+timing+belt.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJh2M_6hmuo9sdKujqoTgeRvyQUSRxSBukfMN7DR76567aniy73TtBFz-u2k1KQS_A2SLyWatjfoJWaArb2mgjCgeRm4wxNvzjKNovFoXVMPU8sQTNEg1FY1rTi8-BiAwVIReWnWIlnjg/s320/New+timing+belt.jpg" width="320" /></a></div>
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Temporary install back the crankshaft pulley and turn the engine clockwise 2 times and check that the timing marks line up according to the service manual. Once satified, install back the TB covers </div>
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Install back the WP pulley and troque down. The crank shaft pulley bolt needs to be torqued down to 180 Nm ( needs to be very tight, it's the only thing that secures the pulley to the crankshaft ). Install back the 2 belts and all the other components in reverse. Make sure there are no extra bolts left and all bolts are torqued down to specification. </div>
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It's a good ideal to replace the valve cover gasket as well. </div>
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Top up the radiator fluid and connect back the spark plugs and batteries terminals are the last to be connected. </div>
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Before you start the engine, make sure all your tools are accounted for. </div>
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Flybywire http://www.blogger.com/profile/12033050948969565462noreply@blogger.com0tag:blogger.com,1999:blog-4428828201756422934.post-18964897362772467622020-02-24T20:06:00.000+08:002020-02-25T09:41:40.916+08:00Classic Mitutoyo 505-626 vernier caliper crystal replacementI inherited my Dad's analogue calipers which was still in good condition except that it had a broken crystal.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEibjdPedAP1BvHMQDEM3JA4cbrDrtITbG5NVTBrpdqCxtJ9mBQGGp_U3fXjanr0tMIN8WzyuhedTgD1UlgQFPYls8Nh5BX2I9NYEgsTFBU8na5VZ8KFVxFb2jGb3vD16IY1E_AjrByfyG8/s1600/20180420_204544.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEibjdPedAP1BvHMQDEM3JA4cbrDrtITbG5NVTBrpdqCxtJ9mBQGGp_U3fXjanr0tMIN8WzyuhedTgD1UlgQFPYls8Nh5BX2I9NYEgsTFBU8na5VZ8KFVxFb2jGb3vD16IY1E_AjrByfyG8/s320/20180420_204544.jpg" width="320" /></a></div>
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The first challenge was to dismantle this caliper and clean it thoroughly but it's not a bed of roses. Built n the 70's, little was known how it was assembled and I had a boggling 3 days of thinking. Finally I placed the bezel against 2 blocks of wood and gave it a hard push. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYK8VvQWqGIRCI6VPSJyd3Ka5PgEWrbbl0-px-AlC8J1rzhxW70nS5C_EvC1nKMNzZn7_0OYSytM-UWZPoHnD1iPQk5uWZU0ICwF3z5FL1rFK7z3NagBIcwJcow9odN8GOLeLS1iXsozE/s1600/Dismantled+calipers.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="576" data-original-width="1024" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYK8VvQWqGIRCI6VPSJyd3Ka5PgEWrbbl0-px-AlC8J1rzhxW70nS5C_EvC1nKMNzZn7_0OYSytM-UWZPoHnD1iPQk5uWZU0ICwF3z5FL1rFK7z3NagBIcwJcow9odN8GOLeLS1iXsozE/s320/Dismantled+calipers.jpg" width="320" /></a></div>
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Inside was so filthy , filled with dust, accumulated dirt and dry grease. So I took out all the parts and cleaned it thoroughly. The bottom picture shows a magnified view of the dial pinion</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgoWlWWVUcHY8xKegAfNjX0x0FMl8gRQepsI7UjBlB7cujSyknqxQss2fg8logswiWW2JNjgLuykHYhzf7ZlGpkmELQzNwRNPifGv_n_9bsIw3GUeygys8XSnavsGNV18C9CXjvkCy4RWQ/s1600/Dirty+pinion.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgoWlWWVUcHY8xKegAfNjX0x0FMl8gRQepsI7UjBlB7cujSyknqxQss2fg8logswiWW2JNjgLuykHYhzf7ZlGpkmELQzNwRNPifGv_n_9bsIw3GUeygys8XSnavsGNV18C9CXjvkCy4RWQ/s320/Dirty+pinion.jpg" width="320" /></a></div>
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The main pinion placed against an Australia 5 cents.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEYn77xz99Pr0CmOsYPI4fBsjfPLY20H3uw7mdTqcB5alUjgh7jTkz-zWvPxtZUWShEMFkd0e5VTe_xuoy3WRpcZCN__kl7zOp3GpMNRpRqRDpzoDf7rlUlDm4IvyUPF8iVsbgSOFWwmY/s1600/20180420_190130.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEYn77xz99Pr0CmOsYPI4fBsjfPLY20H3uw7mdTqcB5alUjgh7jTkz-zWvPxtZUWShEMFkd0e5VTe_xuoy3WRpcZCN__kl7zOp3GpMNRpRqRDpzoDf7rlUlDm4IvyUPF8iVsbgSOFWwmY/s320/20180420_190130.jpg" width="320" /></a></div>
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Below shows the process of derusting parts in a degreaser solvent. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6g-XvRjzt9KBSIzRo4E22pUqXqj7pzYamVCSz2UK4aRblA5MkiFrG-M_ALT4VbWPYhr9asC68hmP6f4s28g6-debvyZIGk5cT-kkkxXA6OQAlMf3Su-Rnpcj4Hj2kfgFiDbuZR1DuLmE/s1600/Derusting.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6g-XvRjzt9KBSIzRo4E22pUqXqj7pzYamVCSz2UK4aRblA5MkiFrG-M_ALT4VbWPYhr9asC68hmP6f4s28g6-debvyZIGk5cT-kkkxXA6OQAlMf3Su-Rnpcj4Hj2kfgFiDbuZR1DuLmE/s320/Derusting.jpg" width="320" /></a></div>
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Below shows a cleaned part</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqv5hu18u_fP8GB0Vi9dA-cD-jUosqPjGyiOjov5XJd9jIVdrtev3xL0w_l2J27N64mD9OTy6vrMTgOzfR4dRgEC73NA83PSruyY64j0NpQTfvON7RVI2LYEHB8AUtQGlQCUKrIsu8_Sg/s1600/20180420_185353.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqv5hu18u_fP8GB0Vi9dA-cD-jUosqPjGyiOjov5XJd9jIVdrtev3xL0w_l2J27N64mD9OTy6vrMTgOzfR4dRgEC73NA83PSruyY64j0NpQTfvON7RVI2LYEHB8AUtQGlQCUKrIsu8_Sg/s320/20180420_185353.jpg" width="320" /></a></div>
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Cleaned up item vs a dirty part. Quite a contrast.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjijzm7n7WW1mNWu2O-DXi8zlGamRWpsUtYzC5OIrLiQ0jW7qyOjEOBbNAndn0EAZ26DtEIwyQ301-ezz2ir-eM034oILMUMXjfmhCeaAEEDGoL9w_RAmVkzgWzpp2fkMbSO0qzvUR7Do8/s1600/Cleaned+up.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjijzm7n7WW1mNWu2O-DXi8zlGamRWpsUtYzC5OIrLiQ0jW7qyOjEOBbNAndn0EAZ26DtEIwyQ301-ezz2ir-eM034oILMUMXjfmhCeaAEEDGoL9w_RAmVkzgWzpp2fkMbSO0qzvUR7Do8/s320/Cleaned+up.jpg" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdDtGvB-f_Th-Icq1y4DRmZUYPDCQnllmt5ouu422VmwloE7bN-s7E_umT8vRJ15royZHk2uuQ9Cmjz1AKSNtNqc-Qp4-TEfny1EFsybN-oEe9ZqP_w-KcG3aj36ssluiOHyNQNdlmXMk/s1600/Dirty+internal+calipers.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdDtGvB-f_Th-Icq1y4DRmZUYPDCQnllmt5ouu422VmwloE7bN-s7E_umT8vRJ15royZHk2uuQ9Cmjz1AKSNtNqc-Qp4-TEfny1EFsybN-oEe9ZqP_w-KcG3aj36ssluiOHyNQNdlmXMk/s320/Dirty+internal+calipers.jpg" width="320" /></a></div>
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Now everything clean, dry and ready for assembly.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEieCcuCxwmR2ItKXbfRdp6Lnv4RISoiGOJrNzMZ9K4-43NGQJLvXyrveJh0ZJVmypyUEiQHyWXcgsIJDSDowvqkyQlPtMz5dO42uposf4bVmjhJi49c2bFF889kMQETl5tMS_mNTQAIjNQ/s1600/All+cleaned+up.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEieCcuCxwmR2ItKXbfRdp6Lnv4RISoiGOJrNzMZ9K4-43NGQJLvXyrveJh0ZJVmypyUEiQHyWXcgsIJDSDowvqkyQlPtMz5dO42uposf4bVmjhJi49c2bFF889kMQETl5tMS_mNTQAIjNQ/s320/All+cleaned+up.jpg" width="320" /></a></div>
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After the cleaning process, I assembled the caliper and check for significant signs of wear and tear. The caliper was still accurate. </div>
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Then comes the next wave of challenge . Replace the broken crystal that has no spare parts. The crystal takes a dome shaped so that it clears the movement of the hand dial during operation but a brand new crystal replacement is just a flat piece of polycarbonate that has to be pressed into the bezel. That means the crystal is slightly bigger that the bezel but it cannot be too big otherwise it will crack during installation. Just a tat bigger.</div>
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The second challenge is to cut a perfectly round polycarbonate. Conventional scissors and penknife is not going to make it. </div>
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The third challenge is to introduce a 5 degree bevel angle to the edge of the crystal's circumference so that when it is pressed in, the crystal's circumference sits squarely to the bezel ( hard to describe) </div>
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The crystal must have a thickness of 0.65mm for it to flex to a dome shape, not any thicker and thinner is not ideal for protection against impact. </div>
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The only way to cut the crystal with all the above properties is the use of a lathe. I used a dremel parting wheel to achieve this . With a special attachment that I have made so that the Dremel tool can be mounted onto the tool post and angled to the required 5 degrees. </div>
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It took 3 attempts to get the right diameter before it was pressed into the bezel.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjXsL43dvgOgF8dbmFl4vk8JlXnYCW1dDf80j0XVkxWnXDbR10xCSeqQiRTIXkGL-FHUbOFkC9g0YP84Bd_50p2xZvQxnQS5vvLqb2Bs54R6gzScuWDMsPcSJG49x1YbE9njaO71hT-N5A/s1600/The+perfect+circle.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1000" data-original-width="1600" height="200" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjXsL43dvgOgF8dbmFl4vk8JlXnYCW1dDf80j0XVkxWnXDbR10xCSeqQiRTIXkGL-FHUbOFkC9g0YP84Bd_50p2xZvQxnQS5vvLqb2Bs54R6gzScuWDMsPcSJG49x1YbE9njaO71hT-N5A/s320/The+perfect+circle.jpg" width="320" /></a></div>
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Below you can see the bevel angle of the crystal. Without this angle the crystal will be seated poorly on the bezel .</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgwwtVNUrrb4YEEFrtfJwiMir7DR3-znyTHeK7O_f9dHJ0INW08bFTusplU_U-GacjztHgxZfWybUieIlzRn6k-PPpYcsfY2z_c0dLbv3dSRLSzggiHCISPe-y85OZ6tsn0r50zNUcGs1U/s1600/20180421_213542.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgwwtVNUrrb4YEEFrtfJwiMir7DR3-znyTHeK7O_f9dHJ0INW08bFTusplU_U-GacjztHgxZfWybUieIlzRn6k-PPpYcsfY2z_c0dLbv3dSRLSzggiHCISPe-y85OZ6tsn0r50zNUcGs1U/s320/20180421_213542.jpg" width="320" /></a></div>
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The final product that's cut out perfectly round .</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjM2nO4g3_6ZgjDyIB8toUQzA3zuUEaoU4R7Yv5It1GMHrVYrZXwULdACK25AElP0l1KrWE6GDv8WDC2M4Y9-VddQt4b7px1sRLmKwYH8a6Wd4BAc9NtCnSkOqT91pBsXS2m8FHA4CQSlM/s1600/New+cut+out+Bezel.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjM2nO4g3_6ZgjDyIB8toUQzA3zuUEaoU4R7Yv5It1GMHrVYrZXwULdACK25AElP0l1KrWE6GDv8WDC2M4Y9-VddQt4b7px1sRLmKwYH8a6Wd4BAc9NtCnSkOqT91pBsXS2m8FHA4CQSlM/s320/New+cut+out+Bezel.jpg" width="320" /></a></div>
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The last challenge is pressing the crystal to the bezel. </div>
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Professional workshop uses a hand press and a dome shaped cup that uniformly presses the crystal into the bezel ( one minute job). I had to use sone household items like a plastic bottle to work the crystal slowly into the bezel. It's one hell of a struggle. When it finally went in, it was such a relief.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhP1B6TAlK_xV9OOi9trW9NP3_FGG79TZx4V8M3uhfEAaRENx4-qnjYCaFE5MYcWDwdh_dMaakTPIo-E2gr66ORIKVSGpPhJcAt5yHzdzTe-NiN-INooyd-1luvBDLhAO8ssLkib2nRMG4/s1600/20180422_143555.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhP1B6TAlK_xV9OOi9trW9NP3_FGG79TZx4V8M3uhfEAaRENx4-qnjYCaFE5MYcWDwdh_dMaakTPIo-E2gr66ORIKVSGpPhJcAt5yHzdzTe-NiN-INooyd-1luvBDLhAO8ssLkib2nRMG4/s320/20180422_143555.jpg" style="opacity: 1;" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6HHUpffhtailfUOOde0aLga0_JW_IHOwNg-U7CtfeqqLuoeBo31uEuhOO2169WMkh9FKKy8ScPtYwpfwfa8MNPfztHUx-DYos_sZZ6aJqHcIs9N7XXl2MBpvXcU4j731xX17iSUyJqHA/s1600/20180422_143712.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6HHUpffhtailfUOOde0aLga0_JW_IHOwNg-U7CtfeqqLuoeBo31uEuhOO2169WMkh9FKKy8ScPtYwpfwfa8MNPfztHUx-DYos_sZZ6aJqHcIs9N7XXl2MBpvXcU4j731xX17iSUyJqHA/s320/20180422_143712.jpg" width="320" /></a></div>
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Took me slightly more than one month to crack this puzzle of crystal replacement .</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEipZ-MQ9C3yv8ZuEeQNlR1936mTtmzwPkj9XZ6qY-qozueTCcEbaaxXZ4J0Cwy6dMn6J6g7vyR7R-JmRnp-EigxkTGLkqjx65O3OivQmB127osKbtetLvTIRdWqPB8YQnufMS37YLf9T7E/s1600/20180422_144920.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="900" data-original-width="1600" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEipZ-MQ9C3yv8ZuEeQNlR1936mTtmzwPkj9XZ6qY-qozueTCcEbaaxXZ4J0Cwy6dMn6J6g7vyR7R-JmRnp-EigxkTGLkqjx65O3OivQmB127osKbtetLvTIRdWqPB8YQnufMS37YLf9T7E/s320/20180422_144920.jpg" width="320" /></a></div>
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Flybywire http://www.blogger.com/profile/12033050948969565462noreply@blogger.com0tag:blogger.com,1999:blog-4428828201756422934.post-76948134689107843112020-02-24T14:56:00.001+08:002020-02-25T05:38:51.724+08:00Super Pacer (Owen Kampten)Built this in April 2012, classic pattern ship. Designed by Owen Kampten.<br />
I converted the Nitro engine into an electric motor. First the wings
ribs were cut out and stick the pieces together. Symmetrical wing foils
are nasty so all the tools came in to help.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjA5egCcTFp0Vq_WysHS4IcZLxZoNmcwoGVPGW_AxwkjcB3owqk_aI2L5FnRLZld-ih5wCjKAfPWo1ft7IRo84g7o2vUiW5AgFiv_M3bEYUWRcrjEf26Tem3E4KsU5Aabx4Crjqxd7Bc90/s1600/P1030855.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjA5egCcTFp0Vq_WysHS4IcZLxZoNmcwoGVPGW_AxwkjcB3owqk_aI2L5FnRLZld-ih5wCjKAfPWo1ft7IRo84g7o2vUiW5AgFiv_M3bEYUWRcrjEf26Tem3E4KsU5Aabx4Crjqxd7Bc90/s320/P1030855.JPG" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiLLOMih2E2qA5etd8S65JgAU_VA8wMdFglXcGtndrqEol2d94uX5KslIxN7cX_JBMX8HYltXOy59Op9isBIePJvPK0TqtHnoWobD8BEdlWaeik-WePHIMO6tEuUssbT-ax_WNaErcUFiE/s1600/P1030853.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiLLOMih2E2qA5etd8S65JgAU_VA8wMdFglXcGtndrqEol2d94uX5KslIxN7cX_JBMX8HYltXOy59Op9isBIePJvPK0TqtHnoWobD8BEdlWaeik-WePHIMO6tEuUssbT-ax_WNaErcUFiE/s320/P1030853.JPG" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFXkz9spaAC2LUCDKzACrw3fIYJjBQK2PGVeyuMx6WXktWwMurZhROM44bpBwvoKyEM8DxNHepPdsJogTCCfn4eSDcCotGCcbN-Nay7KYVbxlCF8xjipn5_htkCV86FfQSjqUuLHDHoIY/s1600/P1030844.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFXkz9spaAC2LUCDKzACrw3fIYJjBQK2PGVeyuMx6WXktWwMurZhROM44bpBwvoKyEM8DxNHepPdsJogTCCfn4eSDcCotGCcbN-Nay7KYVbxlCF8xjipn5_htkCV86FfQSjqUuLHDHoIY/s320/P1030844.JPG" width="320" /></a></div>
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After slotting, stick on the nylon hinge piece to the wing rib<br />
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Making the ailerons using stock triangle but not the right gradient so more work <br />
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Cutting slots in the ailerons to receive the nylon hinges and make the bevel angle for smooth <span style="text-align: center;">movement</span></div>
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According to the plans the wings have a dihedral angle so cut a dihedral brace and test fit the brace. Everything I do must fit in tight
and not too much slop, a habit from too much of helicopter building.</div>
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Next make the aileron torque tube from 3mm carbon steel and brass
bearing for again smooth movement. and solder on the threaded couplers</div>
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Now cut the slot in the Aileron to receive the torque tube</div>
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Don't forget to insert the brass bearing before you close the other end
of the torque tube. Its a night mare to bend these 3mm carbon steel. But
wait there is worse coming. Some pictures</div>
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Stick in the nylon hinges with extra reinforcement.</div>
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Cut the 5mm hard wood which goes to the center rib. Epoxy it to have
strong bond since the wing attaches to the fuse with this hard wood, no
CA for this one.</div>
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Checking for alignment and sticking the lower spar</div>
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Planking the wing's top sheet. </div>
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After planking, glue in the servo bracket and get ready to cut out the servo pocket</div>
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Cut the landing gear support square pegs, X marks the spot for precise drilling</div>
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Sheeting the lower wing leadimg edge</div>
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The remaining servo bracket glue in place</div>
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Glue in the square pegs to support the 5mm landing gear carbon steel wire.</div>
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And yes the nightmare of bending a 5mm landing gear (below picture) to the perfect right angle, pure madness and brute strength<br />
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More pics of the lower spar and the angle joint at the center of the wing</div>
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Next the elevator connect rod and its assembly</div>
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Cut out fuselarge and make the push rod from hard wood round peg and 3mm carbon steel</div>
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Also the former for the wing attachment. A bit too short so CA comes in handy and make up for the length</div>
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Next : Glue the former in place and the triangular stock piece.</div>
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Then comes the motor mount made from 10mm ply with ventilation holes and
glue it in place together with the triangular stock pieces.</div>
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The battery tray is next</div>
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With that done, I cut the rudder and the slots to receive the nylon hinges. Marking the rudder for taper sanding</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiaatYI_perjvWIaH5IEkM5mihy4O3fGS8sQsALkcHK0bCmX9EQJ3IosIb3CW2xX6fy_VNQClTUValPdKeX3ezlUJpuOhvHbwQn7SMeEB4R77Q8alC69wzLiYnRbmjMyO1ZKLZE6PKvLb0/s1600/P1040284.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiaatYI_perjvWIaH5IEkM5mihy4O3fGS8sQsALkcHK0bCmX9EQJ3IosIb3CW2xX6fy_VNQClTUValPdKeX3ezlUJpuOhvHbwQn7SMeEB4R77Q8alC69wzLiYnRbmjMyO1ZKLZE6PKvLb0/s320/P1040284.JPG" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCZ3VDgJz_37DCkhCilGEK4-QP2sX0ZPhvISJoWXWMReJ-XZCwfRmPlccY08pO5IUABBdpUkePcndu2NcxTkAl0b7o6zKa3n_QEeY47rPJH1d4RDYPHMz2o0fjrpUd1OYcmqlaIT7Ebmk/s1600/P1040285.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCZ3VDgJz_37DCkhCilGEK4-QP2sX0ZPhvISJoWXWMReJ-XZCwfRmPlccY08pO5IUABBdpUkePcndu2NcxTkAl0b7o6zKa3n_QEeY47rPJH1d4RDYPHMz2o0fjrpUd1OYcmqlaIT7Ebmk/s320/P1040285.JPG" width="320" /></a></div>
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Planking the bottom of the fuse, cross grain.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_hHCENBvql-an_um5Uw64GtLLYRyXtUjf-j3XnerHQU8Ys5GBBLQk3-Ohg0xlNW6Ey2Bpsp29cF5xdO9JNDBOOcmbj9fOQ2if6HK1xf1tS8ohHYSJCUJpuHC_aj_QikxzwFji6JgyaWY/s1600/P1040292.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_hHCENBvql-an_um5Uw64GtLLYRyXtUjf-j3XnerHQU8Ys5GBBLQk3-Ohg0xlNW6Ey2Bpsp29cF5xdO9JNDBOOcmbj9fOQ2if6HK1xf1tS8ohHYSJCUJpuHC_aj_QikxzwFji6JgyaWY/s320/P1040292.JPG" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhbjlsAHVYWPO4sJV4ONdXSgu_j4srqi7LmybyE34AQtLqaemenefcIWO2ZaYeJk-sXhAqGn1OyQPMS0KpyiqAWwv9XBNut4YLIDfUOxMbt7nRVQf3CBFvLPHMpSx5QztaZi0F89COdac/s1600/P1040293.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhbjlsAHVYWPO4sJV4ONdXSgu_j4srqi7LmybyE34AQtLqaemenefcIWO2ZaYeJk-sXhAqGn1OyQPMS0KpyiqAWwv9XBNut4YLIDfUOxMbt7nRVQf3CBFvLPHMpSx5QztaZi0F89COdac/s320/P1040293.JPG" width="320" /></a></div>
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Next comes the wing tip. Made from balsa block. Did not want to buy as
it was expensive so stick all the balance wood I have and made two
blocks</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhu8BZrnaqU1BklI3EbHgcqjjAyoYib-vx4TkFmXAJBvL-H44I8I0piEwNdKEgd38WxLMjPSUKjad57x3s9olFFIDc4DitwhbTIleXlxVDZpfy3hyXi2XdF6H_R8kfcBQC_z3bMhvtPZik/s1600/P1040299.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhu8BZrnaqU1BklI3EbHgcqjjAyoYib-vx4TkFmXAJBvL-H44I8I0piEwNdKEgd38WxLMjPSUKjad57x3s9olFFIDc4DitwhbTIleXlxVDZpfy3hyXi2XdF6H_R8kfcBQC_z3bMhvtPZik/s320/P1040299.jpg" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAwmMyrHu5Mn2x_1yt7wbgigeCPTaK8bY4gGKmgqGitWzEpl0rhWy4VqVW2_RpktQC1HkviMJwYhBIwspKY79uAGH6cVnW52kRfyOf8iGCWGqtLIm-qz7I_ysiRF5ZC7GqocsPB4D6uCI/s1600/P1040320.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAwmMyrHu5Mn2x_1yt7wbgigeCPTaK8bY4gGKmgqGitWzEpl0rhWy4VqVW2_RpktQC1HkviMJwYhBIwspKY79uAGH6cVnW52kRfyOf8iGCWGqtLIm-qz7I_ysiRF5ZC7GqocsPB4D6uCI/s320/P1040320.jpg" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZ40NlqY-ZwRg3Us_6NXKP_HkLdio0IL-2oF5e50tk6t5D3zXuISpevxNfunqB4E-iX2VllaYfXDEbjJqiPOe-BnYEBzfFDeE6eM6F2f2-lyFYPWMcnpWB6Q3NqEMAJjkqV2vveknuKwI/s1600/P1040322.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZ40NlqY-ZwRg3Us_6NXKP_HkLdio0IL-2oF5e50tk6t5D3zXuISpevxNfunqB4E-iX2VllaYfXDEbjJqiPOe-BnYEBzfFDeE6eM6F2f2-lyFYPWMcnpWB6Q3NqEMAJjkqV2vveknuKwI/s320/P1040322.jpg" width="320" /></a></div>
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Now remove the excess material and sand to shape</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKWCJJOIc0iD2sb102qhyphenhyphenNPVwN1LvZe4AT8O7zxwsXScAgu4I77On6u8uJQy-gUVIZ-487yJTjOaWTxWvagaoWcwtxxOeGzBo8nokppTM1nHMFNlmfHO17QXQdl1eHx_IY4cms9qRHYX0/s1600/P1040325.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKWCJJOIc0iD2sb102qhyphenhyphenNPVwN1LvZe4AT8O7zxwsXScAgu4I77On6u8uJQy-gUVIZ-487yJTjOaWTxWvagaoWcwtxxOeGzBo8nokppTM1nHMFNlmfHO17QXQdl1eHx_IY4cms9qRHYX0/s320/P1040325.jpg" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgf_U3lNBcNkrOAFcH08TXw1cmtGf0POd1UQooUF1Bho5L9Dg3yuv22MrynO3PTZMipl7sib95ZvVA-CP9KgYUGiDhL7P0s11EZFrZwyMxhk_puIZFtWJbjSypKDELDl-ySd0hvzAH0kDM/s1600/P1040328.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgf_U3lNBcNkrOAFcH08TXw1cmtGf0POd1UQooUF1Bho5L9Dg3yuv22MrynO3PTZMipl7sib95ZvVA-CP9KgYUGiDhL7P0s11EZFrZwyMxhk_puIZFtWJbjSypKDELDl-ySd0hvzAH0kDM/s320/P1040328.jpg" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTtd4Qd7ieGXNtzNgdCYe1JMVFzz4wmAAD25WwD4nFEYPg4x7JQ7Q4nBzyLbmvQJ4UqlGNjdngH3nRCoR3c7ScDbMP0mBQ3ssDchdJQ3nfeQ_rhqhfufRtV1Y9-miUDdT9yLwJPNC4bMc/s1600/P1040330.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTtd4Qd7ieGXNtzNgdCYe1JMVFzz4wmAAD25WwD4nFEYPg4x7JQ7Q4nBzyLbmvQJ4UqlGNjdngH3nRCoR3c7ScDbMP0mBQ3ssDchdJQ3nfeQ_rhqhfufRtV1Y9-miUDdT9yLwJPNC4bMc/s320/P1040330.jpg" width="320" /></a></div>
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Wingtip done and servo mounted with aileron in place</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcb4qiutUGz250xJPfewuleeNp4EofT8Fe3yaiHLc000eVaIj_apaefIwF5NHHoafWQB4cAQUv604hbS1PZQ6K0Xj9VqUkF_yxtrE5pFIYy7l-rPMTqTspmwQhyphenhyphenwjo43pAhhSxLWgCUo8/s1600/P1040309.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcb4qiutUGz250xJPfewuleeNp4EofT8Fe3yaiHLc000eVaIj_apaefIwF5NHHoafWQB4cAQUv604hbS1PZQ6K0Xj9VqUkF_yxtrE5pFIYy7l-rPMTqTspmwQhyphenhyphenwjo43pAhhSxLWgCUo8/s320/P1040309.jpg" width="320" /></a></div>
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Next do the wing mounting for the fuse using ply. holes are drilled at
an angle so that the plastic screw sits flush and nice. The two ply are
join at an angle but right angled to the fuse, tricky part, and still
needs to be aligned to the wing's mounting holes.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjT1AFLVVhlNaYAQx_axWklLP7cMX2lO5XNjsSC77-J9rY8tmOG-V-jsXOvfUZiTS7bOI8ckc5EZUkiC7yivcHDkF3fg97mDr05lNUe04OWoXofkfG6ItDC4t-P98C__1agoomhHeDjInM/s1600/P1040311.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjT1AFLVVhlNaYAQx_axWklLP7cMX2lO5XNjsSC77-J9rY8tmOG-V-jsXOvfUZiTS7bOI8ckc5EZUkiC7yivcHDkF3fg97mDr05lNUe04OWoXofkfG6ItDC4t-P98C__1agoomhHeDjInM/s320/P1040311.jpg" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWQj2MFSzHxMbCyRj5IHQdD3qSu_dSllB0YcbsFKTBdq0pjFxOqkawcVZ21-viwAiyPiiX6-XIBWTxyAzg9A45SiCAKRhDw531MkiITjeCxS14mcxCCDLbuxbakxzJDMhUnmzRLBfSlSY/s1600/P1040312.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWQj2MFSzHxMbCyRj5IHQdD3qSu_dSllB0YcbsFKTBdq0pjFxOqkawcVZ21-viwAiyPiiX6-XIBWTxyAzg9A45SiCAKRhDw531MkiITjeCxS14mcxCCDLbuxbakxzJDMhUnmzRLBfSlSY/s320/P1040312.jpg" width="320" /></a></div>
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Next is to bend the 3mm carbon steel for the tail landing gear. Very
hard to bend 90 degree bend and not in xy plane but xyz plane. Don't
forget the brass bearing before the last bent, if not its damn........</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqswV1Za8pSeFufUIyPHkAgZvh4w83lBIxzXJ0NL0cy-CSmRtTLkwSFtywAFZYb2LqfspFqWEuHMrNqCpr4D0i5VWhEvqysBIzqy_RW6c_lTx-Wods9hPSxDvKDbravbI4To9Q1LbtO3k/s1600/P1040384.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqswV1Za8pSeFufUIyPHkAgZvh4w83lBIxzXJ0NL0cy-CSmRtTLkwSFtywAFZYb2LqfspFqWEuHMrNqCpr4D0i5VWhEvqysBIzqy_RW6c_lTx-Wods9hPSxDvKDbravbI4To9Q1LbtO3k/s320/P1040384.JPG" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbx3RkQP2xz93B6UGqHozsTRkJvs2hgri7dJLDFD4IPg06yqC_du0y_c_8g_op6HWTqM24sXdf38W4xxAJ-lS9-8yfUmBVH7KCiZZdM6EE2CXB5voD2sNTi-R0hNK5XOVCI3TlJ5uI9mA/s1600/P1040336.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbx3RkQP2xz93B6UGqHozsTRkJvs2hgri7dJLDFD4IPg06yqC_du0y_c_8g_op6HWTqM24sXdf38W4xxAJ-lS9-8yfUmBVH7KCiZZdM6EE2CXB5voD2sNTi-R0hNK5XOVCI3TlJ5uI9mA/s320/P1040336.jpg" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgsIn-ne53MistmaH7n0xerB8rFqza0ZcC5Zk7hwQU3hV2rvw6j8_z905vY_iU-gxLC0p-9UcNa-uzHrfyI36KFxyHY5v72QjfxkTVOla5U81o2OHezog-dDXnMNO8_721vm7vyDdr1cXY/s1600/P1040383.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgsIn-ne53MistmaH7n0xerB8rFqza0ZcC5Zk7hwQU3hV2rvw6j8_z905vY_iU-gxLC0p-9UcNa-uzHrfyI36KFxyHY5v72QjfxkTVOla5U81o2OHezog-dDXnMNO8_721vm7vyDdr1cXY/s320/P1040383.JPG" width="320" /></a></div>
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Now a little mod to the tail wheels. To make the plane as light, I chose
the plastic wheels. But it is not smooth so I added brass bearing in
the wheel so that it rotates on the steel landing gear, get the idea? Ok
a pic is worth a thousand words. Look carefully, you can see the brass
tube. Add a drop of oil and its ultra smooth. The wheel has almost no
weight and with this mod it will last a long time and more importantly
it rolls perfectly straight so that take off is true.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzPPC9_CzfI32HdR7LPJl1mRAh6O5XQg7ZEu4LpgU4RBZE03rsM1u9Yt5RkfKBTQO_S1_AnjXK41KH24oh5UbABhMQziXnJFRz9gZ_sb9Xlp9LZmxSzVZAwIc97WbNVt2s6i0LcQWz7NI/s1600/P1040388.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzPPC9_CzfI32HdR7LPJl1mRAh6O5XQg7ZEu4LpgU4RBZE03rsM1u9Yt5RkfKBTQO_S1_AnjXK41KH24oh5UbABhMQziXnJFRz9gZ_sb9Xlp9LZmxSzVZAwIc97WbNVt2s6i0LcQWz7NI/s320/P1040388.jpg" width="320" /></a></div>
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The horizontal stab with holes shed off 2 grams of weight.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhdNmJS4Xv3KCiB2qCNyhNxX7igPU9028z23vuAR287-txY63fa36le8ElCBVtaqTBO319-vBKJOWlax9CZdFdbXSZhVe9bSlcq-yuLuyym1pFVpN2XOFlphey54mgGcULJ5ruW-KnjuQM/s1600/P1040364.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhdNmJS4Xv3KCiB2qCNyhNxX7igPU9028z23vuAR287-txY63fa36le8ElCBVtaqTBO319-vBKJOWlax9CZdFdbXSZhVe9bSlcq-yuLuyym1pFVpN2XOFlphey54mgGcULJ5ruW-KnjuQM/s320/P1040364.jpg" width="320" /></a></div>
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Mould the aircraft's canopy. a picture is worth a thousand words. </div>
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Complete the build of the Super Pacer</div>
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Flies like a dream!!</div>
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With 9x 8 prop drawing 32A, plenty room for improvement. Could fit a 10 x
7 prop with 42A draw. The flight was good, rolls were axial in both
directions. Model flew straight and true. Very happy! 6 minutes of
flight time, landed at 3.8 V per cell (3s 2700mah).
</div>
Flybywire http://www.blogger.com/profile/12033050948969565462noreply@blogger.com0tag:blogger.com,1999:blog-4428828201756422934.post-45488941560381523892010-09-26T23:29:00.455+08:002011-05-15T01:14:21.534+08:00My Scratch Build Guppy<div style="clear: left; cssfloat: left; float: left; margin-bottom: 1em; margin-right: 1em; text-align: left;"></div><div style="border-bottom: medium none; border-left: medium none; border-right: medium none; border-top: medium none; text-align: left;"><br />
</div><div align="left" style="border-bottom: medium none; border-left: medium none; border-right: medium none; border-top: medium none; text-align: justify;"><br />
</div><div style="border-bottom: medium none; border-left: medium none; border-right: medium none; border-top: medium none; text-align: justify;">After flying RC helicopters for some time, I reckon that it was time to look at some aircraft. I was fascinated with electric gliders. Its magestic and graceful flight in the air sent me shopping for one. </div><div style="border-bottom: medium none; border-left: medium none; border-right: medium none; border-top: medium none; text-align: justify;">I set my eyes on some OK models mainly Tumeric, Stevia, Oregano, Citron , Majoram and Mace. All were great looking planes and all have low wing loading. But there was one problem, the price was too expensive for me to buy it and I did not like the idea of having a generic aircraft that others could also easily own one.</div><div style="border-bottom: medium none; border-left: medium none; border-right: medium none; border-top: medium none; text-align: justify;">So I decided to save some money and build one. I happen to be good with tools and hand work. I decided on one glider which was the Guppy. This was also my first scratch build after so many years. </div><div style="border-bottom: medium none; border-left: medium none; border-right: medium none; border-top: medium none; text-align: left;"><br />
</div><div style="border-bottom: medium none; border-left: medium none; border-right: medium none; border-top: medium none; text-align: left;">When I was younger in my student days, I build with my Dad some simple models. </div><div style="border-bottom: medium none; border-left: medium none; border-right: medium none; border-top: medium none; text-align: left;"><br />
</div><div style="border-bottom: medium none; border-left: medium none; border-right: medium none; border-top: medium none; text-align: justify;">Here is one pic of the Guppy plan.</div><div style="border-bottom: medium none; border-left: medium none; border-right: medium none; border-top: medium none; text-align: justify;"><div class="separator" style="clear: both; text-align: center;"></div><div style="border-bottom: medium none; border-left: medium none; border-right: medium none; border-top: medium none;"><br />
</div></div><div class="separator" style="border-bottom: medium none; border-left: medium none; border-right: medium none; border-top: medium none; clear: both; text-align: justify;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWLZiKocp8YPHmPUv7y6vdQmWERqXwKZki8AJlJ5y571VAr6OjdK_G36a-K0bKbnrLzeozzXM2g9niRv8mcSUNOHpPyfjylzxegcXWDh6PcTcw1EBiFcYuz7AARBSECaF58O27RhXfrYI/s1600/P1030419.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240px" px="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWLZiKocp8YPHmPUv7y6vdQmWERqXwKZki8AJlJ5y571VAr6OjdK_G36a-K0bKbnrLzeozzXM2g9niRv8mcSUNOHpPyfjylzxegcXWDh6PcTcw1EBiFcYuz7AARBSECaF58O27RhXfrYI/s320/P1030419.JPG" width="320px" /></a></div><div style="text-align: justify;">The designer of this plane was NOT me. I got the plan printed in full scale and checked the dimension of the wings which measured 1.5 meters. <br />
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The build then started on the Aug 2009. Parts had to be hand cut from Balsa sheets. Every piece was hand cut and my index fingers started to sore especially cutting thicker balsa sheets. Part count was nearly hundred, but not all were cut on the same day and it cannot be done so. </div><div style="text-align: justify;"><br />
</div><div style="text-align: justify;">I started building the wings first. Wing ribs were cut first and the wing spars were glue onto the sheeting to provide a base for the ribs to sit on flat. With so many ribs, some ribs were under cut and some over size. But all have to be corrected to the same profile using sand paper.</div><div style="text-align: justify;"><br />
</div><div style="text-align: justify;">Most people would use pins to hold the parts down during the gluing process but I did not like the idea of leaving holes in my model so I went for another approach. There is more than one way to skin a cat.</div><div style="text-align: justify;"> </div><div style="text-align: justify;">Some pics of the wings done up </div><div style="text-align: justify;"></div><div style="text-align: justify;"><div style="clear: left; cssfloat: left; float: left; margin-bottom: 1em; margin-right: 1em; text-align: left;"><img border="0" height="240px" j8="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrjtt8N0W5TdHzizFC87toP1EdDmwgt0G63ZqYYUnbKv8Zrdk3916C8URWaAn0CNyDs_sVUsxIG4bLzod0MxihyphenhyphenXV8N-5lTuSJLmveZMpvrL_7bVK7agG-yHeHUt6nRzBnUKqqsvl0PC8/s320/P1040038.JPG" width="320px" /></div></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiiyD43-29zqUJ6uD8qG2AyLnTwSXos1r41qW0lSdZ7G6rKPJ1kEm47vWKYCTRoPXuwRunyFXrvKJSaYnaZw5SuVhYKQfHCXUtPGPRWnaneq50zGynhymu9ippXZ_1MaDHEF7HlJHbkzy8/s1600/P1040069.JPG" imageanchor="1" style="clear: left; cssfloat: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240px" j8="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiiyD43-29zqUJ6uD8qG2AyLnTwSXos1r41qW0lSdZ7G6rKPJ1kEm47vWKYCTRoPXuwRunyFXrvKJSaYnaZw5SuVhYKQfHCXUtPGPRWnaneq50zGynhymu9ippXZ_1MaDHEF7HlJHbkzy8/s320/P1040069.JPG" width="320px" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiBkqZcxyu2WRX7IcehXeTHdX8xVXpIVr9ASQ3dBzDJBRYq_MDGdUpcU4tp-ttKis4DVyYRMCLG_SiX2uWZBDQSvgg4TSnsMH9Bwp0xlPCXz2u8rrqTaR2xuMOE_ydrn9h9YsULpg7LXV0/s1600/P1040072.JPG" imageanchor="1" style="clear: left; cssfloat: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240px" j8="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiBkqZcxyu2WRX7IcehXeTHdX8xVXpIVr9ASQ3dBzDJBRYq_MDGdUpcU4tp-ttKis4DVyYRMCLG_SiX2uWZBDQSvgg4TSnsMH9Bwp0xlPCXz2u8rrqTaR2xuMOE_ydrn9h9YsULpg7LXV0/s320/P1040072.JPG" width="320px" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhefDPVTGuu4mRKC-WZUUgPd0rcxajUy2V3W5SXbX_vQQ6_ZOsg6dqACP_eVQDRGf3BdocNZQTkZ8zga1nz_pP2Gpq9XBcXECBFBnJvsaOhDqQ5VdDFcAJtHauoWgb1RKBQWOm85Ai15DQ/s1600/P1040071.JPG" imageanchor="1" style="clear: left; cssfloat: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240px" j8="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhefDPVTGuu4mRKC-WZUUgPd0rcxajUy2V3W5SXbX_vQQ6_ZOsg6dqACP_eVQDRGf3BdocNZQTkZ8zga1nz_pP2Gpq9XBcXECBFBnJvsaOhDqQ5VdDFcAJtHauoWgb1RKBQWOm85Ai15DQ/s320/P1040071.JPG" width="320px" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjnOyOKLX6D7boB-xMDVuEJ9mEvGxmZUiCg-RQ6GQbxDAyaqTVDMGKhQJ7bEn5_EHRmTYoB36NxHVFNWD8uSUhZqH_ahIy87CLqgS-SZ2nZ_-FWGJNnZqBz_bzX9H2e-md_dlWLnyJEbAw/s1600/P1040070.JPG" imageanchor="1" style="clear: right; cssfloat: right; float: right; height: 168px; margin-bottom: 1em; margin-left: 1em; width: 260px;"></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbqwJiisEBUnlT-3xhRqwuRkKvLKZOsKduOfllbQcCGlhOJfs5_HR_rASTdKmcPwH56V9QSNto6uDBz-mpnrAGbaCvdLDfI8jX-W2CYmzRs8w77ODbOhT0BDF3cCIOchUZj0K1a1UKt10/s1600/P1020857.JPG" imageanchor="1" style="clear: left; cssfloat: left; float: left; margin-bottom: 1em; margin-right: 1em;"></a></div><div style="text-align: justify;"><div style="clear: left; cssfloat: left; float: left; margin-bottom: 1em; margin-right: 1em;"> <img border="0" height="240px" j8="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjnOyOKLX6D7boB-xMDVuEJ9mEvGxmZUiCg-RQ6GQbxDAyaqTVDMGKhQJ7bEn5_EHRmTYoB36NxHVFNWD8uSUhZqH_ahIy87CLqgS-SZ2nZ_-FWGJNnZqBz_bzX9H2e-md_dlWLnyJEbAw/s320/P1040070.JPG" width="320px" /></div><br />
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<img border="0" height="240px" j8="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgeuDEX1LG4eALTKn0BL91ld-DN3KvowacDjFb1z14yZroEpYwdi4WITYmEOxFiuB_7p0lEInM53mUndVb23dIl78JH8KRIMRRUB4SPvrFffCGwSKdvZn1duGP3pDgzr226xmUSBo8jA7Q/s320/P1040075.JPG" width="320px" /><br />
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</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjF4b26ILFhTAFQlDrzTuZdfy9XCikgiOwwg8u541TBrFzrGOVV7QbujbvoYlhT0KSo7YJxiDdQ2fDxSwMzCMhLpcsxbYSjI5SjwkCHoll4yYv3s-RysPzAk-Edu_DBFYbfWwEiTf5B-o/s1600/P1040078.JPG" imageanchor="1" style="clear: right; cssfloat: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="240px" j8="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjF4b26ILFhTAFQlDrzTuZdfy9XCikgiOwwg8u541TBrFzrGOVV7QbujbvoYlhT0KSo7YJxiDdQ2fDxSwMzCMhLpcsxbYSjI5SjwkCHoll4yYv3s-RysPzAk-Edu_DBFYbfWwEiTf5B-o/s320/P1040078.JPG" width="320px" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgHOSVsC9kGUNZDUq4ET6pRkRNi1CNsENiPKjNY6R5Inpb7n8H8CrHs_hqZ4r7bCs52LAhIsFQlN8xi_vL3QoWsliA9RrYTaM1x3rWTmUp_k83VSRmRYFINOw5NWEURul92I0SGwbZer8/s1600/P1040076.JPG" imageanchor="1" style="clear: left; cssfloat: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240px" j8="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgHOSVsC9kGUNZDUq4ET6pRkRNi1CNsENiPKjNY6R5Inpb7n8H8CrHs_hqZ4r7bCs52LAhIsFQlN8xi_vL3QoWsliA9RrYTaM1x3rWTmUp_k83VSRmRYFINOw5NWEURul92I0SGwbZer8/s320/P1040076.JPG" width="320px" /></a></div><div style="text-align: justify;"> <img border="0" height="240px" px="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbqwJiisEBUnlT-3xhRqwuRkKvLKZOsKduOfllbQcCGlhOJfs5_HR_rASTdKmcPwH56V9QSNto6uDBz-mpnrAGbaCvdLDfI8jX-W2CYmzRs8w77ODbOhT0BDF3cCIOchUZj0K1a1UKt10/s320/P1020857.JPG" width="320px" /><img border="0" height="240px" px="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPKb78ds9fR-DLjkZuPuXxeN_cTM1XqPAouP3LaRb7Kak2IElL5_GPkAFL-UF9KOgaUxVWZDsRm89f6R3jp8c4GVdC40OejZP8-V4SBfQY5W2PgwDM3fOUT17x3jwK6sSEGbcNEKxCsLU/s320/Wings+on+plan.JPG" width="320px" /></div><div style="text-align: justify;">I will disclose the mystery of the toes and CD cover later. Nice toes right? Ha ha! </div><div style="text-align: justify;">Then came the upper wing sheeting. This was easy for the main wings. But when I was gluing the wing tip, how do i introduce the wing twist while waiting for the upper 1 mm balsa sheeting to cure? ( The answer to the toes and CD cover). How do I achieve two things at the same time? <br />
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The wing twist was critical, it helps the glider to roll. Without the twist, the glider would just yaw left and right since the Guppy has no ailerons. I thought about the problem for some days and then came out with the solution of using a flat plywood drilled with holes and fit it with rivet to hold rubber bands. These rubber bands would hold down the top balsa sheeting and at the same time introducing the wing twist! <br />
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And thus was born the jigging device to hold rubber bands in place. <br />
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Some pics to show the process.</div><div style="text-align: justify;"><br />
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<table cellpadding="0" cellspacing="0" class="tr-caption-container" style="float: left; margin-right: 1em; text-align: left;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg36XhczSZlbMeOVkLXWt3VDvTwyvUFLCK6YgBhs_7E5OuolKuucPr9ZHxY44UXpsfMySg4l5Twzp2JCjZWBdO59uf4hcVFLiwaVQNvxy0x9YJ-Yc92voINVnZMC6I9k3fGCIHwmK88zSY/s1600/P1040102.JPG" imageanchor="1" style="clear: left; cssfloat: left; margin-bottom: 1em; margin-left: auto; margin-right: auto;"><img border="0" height="240px" j8="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg36XhczSZlbMeOVkLXWt3VDvTwyvUFLCK6YgBhs_7E5OuolKuucPr9ZHxY44UXpsfMySg4l5Twzp2JCjZWBdO59uf4hcVFLiwaVQNvxy0x9YJ-Yc92voINVnZMC6I9k3fGCIHwmK88zSY/s320/P1040102.JPG" width="320px" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Winglet sheeting</td></tr>
</tbody></table> <br />
<table cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVWH1rgvBk3OT0itKeHKett59Szy8AqNYRwca9-5TSmFE3mE5iS2K85_QR1-0CmNDFHMg8U7WL1DX4QbP737xhm-07ntemgQ24Np6BDDwECg9iceLQm1r6W7GVkrEPLp_aSwEunMISZl4/s1600/rubber+band+on+rig.JPG" imageanchor="1" style="clear: left; cssfloat: left; margin-bottom: 1em; margin-left: auto; margin-right: auto;"><img border="0" height="121px" px="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVWH1rgvBk3OT0itKeHKett59Szy8AqNYRwca9-5TSmFE3mE5iS2K85_QR1-0CmNDFHMg8U7WL1DX4QbP737xhm-07ntemgQ24Np6BDDwECg9iceLQm1r6W7GVkrEPLp_aSwEunMISZl4/s320/rubber+band+on+rig.JPG" width="320px" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Main wing sheeting</td></tr>
</tbody></table>After that the sanding of the leading edge was performed to get the right profile. <br />
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</div><div style="text-align: justify;">The making process was fun until the wing tips. Because the plan does not show in three dimension, I had to imagine the wing tip combining all the data from the plans. I still did not get it and first few tries were wrong.</div><div style="text-align: justify;"><br />
</div><div class="separator" style="clear: both; text-align: justify;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgaXbqlSvdZdIgjW1UmpyuzSIlHsleirfpNldbaRbC9-wFRoPeohRwIAR8vV-oufHjCbf-uYD0DeLV5FNeO5xohENpdSloFRJ6yKvbR0Biu9UEVYIw_DMqa0jSaIedodEk-hGTDJC_SSyM/s1600/P1020849.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240px" px="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgaXbqlSvdZdIgjW1UmpyuzSIlHsleirfpNldbaRbC9-wFRoPeohRwIAR8vV-oufHjCbf-uYD0DeLV5FNeO5xohENpdSloFRJ6yKvbR0Biu9UEVYIw_DMqa0jSaIedodEk-hGTDJC_SSyM/s320/P1020849.jpg" width="320px" /></a></div><div style="text-align: justify;">I made 3 attempts to get the wing tips. On the second try, I ask the internet forum for some help and they showed me some pics of the wing tips. The wing tips are carved out from thick balsa block. On the third try, I succeeded and the room was full of balsa dust and of course I breath in some.</div><div style="text-align: justify;"><br />
Because the tips were very fragile, I glassed it with fiber cloth and epoxy. Then the same was done for the right wing, mind you both had to be symmetrical.</div><div style="text-align: justify;"><div style="border-bottom: medium none; border-left: medium none; border-right: medium none; border-top: medium none;"><br />
</div><div class="separator" style="border-bottom: medium none; border-left: medium none; border-right: medium none; border-top: medium none; clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhObAn92V_aSy0bjJlWhVeay6zTT4eSMosGd9gQzuj-3jK8LE4S5MwH4Mt1FXxnPQ8Dy3VNv3mYNINvD3YJWVNrryB1QD03m-eFbiLX_5Pv2-QR0RVMzeG5XvyOfZJKsT6JUhKSvLIX2n4/s1600/P1040082.JPG" imageanchor="1" style="clear: right; cssfloat: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="240px" j8="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhObAn92V_aSy0bjJlWhVeay6zTT4eSMosGd9gQzuj-3jK8LE4S5MwH4Mt1FXxnPQ8Dy3VNv3mYNINvD3YJWVNrryB1QD03m-eFbiLX_5Pv2-QR0RVMzeG5XvyOfZJKsT6JUhKSvLIX2n4/s320/P1040082.JPG" width="320px" /></a></div><div style="border-bottom: medium none; border-left: medium none; border-right: medium none; border-top: medium none;"><div style="border-bottom: medium none; border-left: medium none; border-right: medium none; border-top: medium none;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8gTmRVF9aOKuQMHcCXDiYXarmNynFcePzuIAmK9m_fXsVg3wTQZP5hsGguqFd5uZVLs3lMzP4SLUUx5lKOe4v7kQBoS-JjaxT5VX_jqaYhwbIToS1aDbm073siNtxCYq4LJ-eV7MQVt0/s1600/P1040080.JPG" imageanchor="1" style="clear: left; cssfloat: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240px" j8="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8gTmRVF9aOKuQMHcCXDiYXarmNynFcePzuIAmK9m_fXsVg3wTQZP5hsGguqFd5uZVLs3lMzP4SLUUx5lKOe4v7kQBoS-JjaxT5VX_jqaYhwbIToS1aDbm073siNtxCYq4LJ-eV7MQVt0/s320/P1040080.JPG" width="320px" /></a> </div> <br />
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfqSpqNwi2ooSCrYaWfxClCg962TIXv6zwdN7IbsTDdlAlwMnZFherl6ULxVA-HWz87-9p6MJ2a_q0UFZ-jg-iMq-ctaRDlXNZOEWE1CqPp1sw6qMl6ryMTbMGj9XbHivnFC9iroYyTU0/s1600/P1040091.JPG" imageanchor="1" style="clear: left; cssfloat: left; margin-bottom: 1em; margin-left: auto; margin-right: auto;"><img border="0" height="240px" j8="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfqSpqNwi2ooSCrYaWfxClCg962TIXv6zwdN7IbsTDdlAlwMnZFherl6ULxVA-HWz87-9p6MJ2a_q0UFZ-jg-iMq-ctaRDlXNZOEWE1CqPp1sw6qMl6ryMTbMGj9XbHivnFC9iroYyTU0/s320/P1040091.JPG" width="320px" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Checking for symmetry</td></tr>
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<tr><td style="text-align: center;"><img border="0" height="240px" px="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEglwR73xeedlrzGbEgQ5vgsHaT5x6y7d0Tdf_AzORnoGvZmBcEIWNn3OUmPqJBJPotOgeL7FO7SACHamtw-qAamMnekSgoy0W40gUoXkRaci6h-0WYPf3bXAmblvOgGnOx1UqpjIorSEOs/s320/P1020855.JPG" style="margin-left: auto; margin-right: auto;" width="320px" /></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Test fit of wing tip</td></tr>
</tbody></table></div><div style="border-bottom: medium none; border-left: medium none; border-right: medium none; border-top: medium none;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioQIBGMogdNhGFgcYnK7Lbzg0axpYMn3xldkxYuV3V35logd6f9ub1nw60UTkq7FZ4B7Amg_PFJWmhlkiuyAFGPfDo99QPzQsELmoZ5moTHkbIBOcgR-oMmXyhObLSy19Ommgk-GpYVAA/s1600/P1040090.JPG" imageanchor="1" style="clear: left; cssfloat: left; float: left; margin-bottom: 1em; margin-right: 1em;"></a></div><div style="border-bottom: medium none; border-left: medium none; border-right: medium none; border-top: medium none;"><br />
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgxdDwIdh9RUwKPsGtQy-jSrS8TP0iycfsKkOqst_DXoCCGpQ0yvDLttDFVlhU__eq2Y2DiCut2HOtP8V0dvEzyINlK41nD5q9pgPLmMpMjidyEYCwAXMAOM5Hu7w56uujns0V8kKSu0ws/s1600/P1040093.JPG" imageanchor="1" style="clear: left; cssfloat: left; margin-bottom: 1em; margin-left: auto; margin-right: auto;"><img border="0" height="240px" j8="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgxdDwIdh9RUwKPsGtQy-jSrS8TP0iycfsKkOqst_DXoCCGpQ0yvDLttDFVlhU__eq2Y2DiCut2HOtP8V0dvEzyINlK41nD5q9pgPLmMpMjidyEYCwAXMAOM5Hu7w56uujns0V8kKSu0ws/s320/P1040093.JPG" width="320px" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Checking for symmetry <br />
after gluing to winglet</td></tr>
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With the wings done, I proceed to make the fuselage which was two parts joined together. The bottom of the fuse was curved and I had to make a styrofoam box to force out the shape. The Balsa wood was left overnight to take shape. You can see the shape of the final wood in the pic. Then it was cut to the exact shape and bonded to the side pieces. </div><div style="border-bottom: medium none; border-left: medium none; border-right: medium none; border-top: medium none;"><br />
</div></div></div></div><div class="separator" style="clear: both; text-align: justify;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiR7knDmwtTX1_i6V5hNXM84bHDPnYE-YVfViCEqDrW_0dDneB7lqehp6KTZmrjs65rCaVmpKTvQ-aLZaZvxVjl5vmMcNIjOjtkr1VQQXZyFDHuF4px4EjBhH3uVL1EUkxPCrAsU0SUKwA/s1600/Styroform+mould.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240px" px="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiR7knDmwtTX1_i6V5hNXM84bHDPnYE-YVfViCEqDrW_0dDneB7lqehp6KTZmrjs65rCaVmpKTvQ-aLZaZvxVjl5vmMcNIjOjtkr1VQQXZyFDHuF4px4EjBhH3uVL1EUkxPCrAsU0SUKwA/s320/Styroform+mould.JPG" width="320px" /></a></div><div style="text-align: justify;"><br />
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</div><div style="border-bottom: medium none; border-left: medium none; border-right: medium none; border-top: medium none; text-align: justify;">The bulkheads were also cut out but its ply wood. They serve as wing attachment points. The ply wood was also very hard to cut to the exact size since they are very hard, don't bother with the pen knife, I went for the saw approach. Wish I had powered table bench saw. I increased the thickness of the bulkheads to receive the plastic bolts so I did not have to use a metal nut.<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDb-ieduSC9pJhwo30suzcUhoKrhJS8wqUB7Im_k_lBckjkO5CF0VNpBngDkqS4iqVEuLZ7yiZpkrkc7avccVXhoWWNSxX7o6qoHiMWXt1Jm_FtZYGltv9ENyibLpiUbvw1afc3DRtAwg/s1600/P1040067.JPG" imageanchor="1" style="clear: left; cssfloat: right; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240px" j8="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDb-ieduSC9pJhwo30suzcUhoKrhJS8wqUB7Im_k_lBckjkO5CF0VNpBngDkqS4iqVEuLZ7yiZpkrkc7avccVXhoWWNSxX7o6qoHiMWXt1Jm_FtZYGltv9ENyibLpiUbvw1afc3DRtAwg/s320/P1040067.JPG" width="320px" /></a></div><div style="border-bottom: medium none; border-left: medium none; border-right: medium none; border-top: medium none;"><table cellpadding="0" cellspacing="0" class="tr-caption-container" style="float: left; margin-right: 1em; text-align: left;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_Kgjqf1BTmzE4tLNYY7cdDfVLJcr60nav0g0hTGHfLv94r1dCD_aKDDECdSNIRaI3bqZwsez6caqCrmg7gTa6GflW7ngTw8N203DCfTkm8xEw_awcnqgGVpFbP9YnmoHppnjRiPBZW0U/s1600/P1040066.JPG" imageanchor="1" style="clear: left; cssfloat: left; margin-bottom: 1em; margin-left: auto; margin-right: auto;"><img border="0" height="240px" j8="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_Kgjqf1BTmzE4tLNYY7cdDfVLJcr60nav0g0hTGHfLv94r1dCD_aKDDECdSNIRaI3bqZwsez6caqCrmg7gTa6GflW7ngTw8N203DCfTkm8xEw_awcnqgGVpFbP9YnmoHppnjRiPBZW0U/s320/P1040066.JPG" width="320px" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Rear former, notice the bevel edge <br />
necessary later for gluing</td></tr>
</tbody></table></div><br />
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg6VuKEXml21YJUFOg2dSpq0xMnoH_dUGRcfVItHMHoH1Fz3p1QTq4odS8TCmDnafLGSO3gVIRq-rw8bgsJ8kAtpYcdCdodO47KgbGGvImnVI8Beu_ZVlKQwM8PTjQ-6KIauRwbqInh3_A/s1600/P1030023.JPG" imageanchor="1" style="clear: left; cssfloat: left; margin-bottom: 1em; margin-left: auto; margin-right: auto;"><img border="0" height="240px" px="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg6VuKEXml21YJUFOg2dSpq0xMnoH_dUGRcfVItHMHoH1Fz3p1QTq4odS8TCmDnafLGSO3gVIRq-rw8bgsJ8kAtpYcdCdodO47KgbGGvImnVI8Beu_ZVlKQwM8PTjQ-6KIauRwbqInh3_A/s320/P1030023.JPG" width="320px" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Gluing the front former</td></tr>
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjslixnenhI7Hz9l96Xc8fgeyMIWigknFxqVqu2ZixrYzH0v0w8IddYaHLmOCIVmvBwxzq7Wme6XbClrV4atBgrxWLsCAzUXyuEG1MUPvJB7lxtCb44LF7QwRh3rREyPUFEC6f5zQg_gJA/s1600/P1040138.JPG" imageanchor="1" style="clear: left; cssfloat: right; margin-bottom: 1em; margin-left: auto; margin-right: auto;"><img border="0" height="240px" j8="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjslixnenhI7Hz9l96Xc8fgeyMIWigknFxqVqu2ZixrYzH0v0w8IddYaHLmOCIVmvBwxzq7Wme6XbClrV4atBgrxWLsCAzUXyuEG1MUPvJB7lxtCb44LF7QwRh3rREyPUFEC6f5zQg_gJA/s320/P1040138.JPG" width="320px" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Gluing the motor mount </td></tr>
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With that done, I glued everything in place and proceed to mate the tail part to the front fuselage.</div><div style="text-align: justify;"><br />
</div><div style="text-align: justify;">The fuselarge also needed triangular strips and had to be cut in a particular grain direction so that it fits the at right angle but able to bend slightly. This part has to be cut carefully as it is the only material that holds the sides to the bottom piece when the fuse is sanded to the final curves, see the plans carefully and you will know what I mean.. The author suggested using a saw to cut it but after a few attempts I gave up and use another approach, power tools!</div><div style="text-align: justify;"><br />
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSjma2M2Owb3Bmm71ckjW_vYhk7U_-3P2nswIRHth_RY1soLezdT8eDAHIfVHFDBpQI-EXvA_QETZgZryJ9lz3TNU-8razLzoKJ5T6-eVygHe5j05CTocaHEoKUn9NkWf3Y8qwWCUVe4A/s1600/P1040145.JPG" imageanchor="1" style="clear: left; cssfloat: left; margin-bottom: 1em; margin-left: auto; margin-right: auto;"><img border="0" height="240px" j8="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSjma2M2Owb3Bmm71ckjW_vYhk7U_-3P2nswIRHth_RY1soLezdT8eDAHIfVHFDBpQI-EXvA_QETZgZryJ9lz3TNU-8razLzoKJ5T6-eVygHe5j05CTocaHEoKUn9NkWf3Y8qwWCUVe4A/s320/P1040145.JPG" width="320px" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">When cut correctly two pieces of triangular strip <br />
makes a perfect square</td></tr>
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Some pics of the triangular strips in place</div><div style="text-align: justify;"><br />
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</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjVJKewMNNWWV0j-5H1gO0zWMlkOkWI0toHjghFrpjNT-2gyEzV0_LOhVPZOIzmuIvj992s4aoOTYlJ-3916YOemlCuyWKBZAvAXTdqJUR-NLjmIDzHSjzk9P6fNe6T4TmXEp09mmbS1c8/s1600/P1040150.JPG" imageanchor="1" style="clear: right; cssfloat: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="240px" j8="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjVJKewMNNWWV0j-5H1gO0zWMlkOkWI0toHjghFrpjNT-2gyEzV0_LOhVPZOIzmuIvj992s4aoOTYlJ-3916YOemlCuyWKBZAvAXTdqJUR-NLjmIDzHSjzk9P6fNe6T4TmXEp09mmbS1c8/s320/P1040150.JPG" width="320px" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2pXz3-Hb30koFO0HVT1iHI7jNWtSxCD6qJB-O9XTb_RzPa_bFI7Xtum9SDdJ_i0noU6nhMuzL199VJTCyYpssBapRqwxle9IGMLB1MesfMf-PZKg11wMtWwVyCsEO03SILjJlVD0tylw/s1600/P1040149.JPG" imageanchor="1" style="clear: left; cssfloat: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240px" j8="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2pXz3-Hb30koFO0HVT1iHI7jNWtSxCD6qJB-O9XTb_RzPa_bFI7Xtum9SDdJ_i0noU6nhMuzL199VJTCyYpssBapRqwxle9IGMLB1MesfMf-PZKg11wMtWwVyCsEO03SILjJlVD0tylw/s320/P1040149.JPG" width="320px" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhGcyNwYTsCo4Cvb-zuxmsU4QfX3o0JVHSzcp2h5YYC56f_t8oeLwi9S4PBfUBIeYQSQ77V6eBkTKLP0PLf20_X6usmCsgy_IyB55gIVLKnZMftk6ZtNhE-W2eqU6yqkQXPMuAZb194iJs/s1600/P1040147.JPG" imageanchor="1" style="clear: right; cssfloat: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="240px" j8="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhGcyNwYTsCo4Cvb-zuxmsU4QfX3o0JVHSzcp2h5YYC56f_t8oeLwi9S4PBfUBIeYQSQ77V6eBkTKLP0PLf20_X6usmCsgy_IyB55gIVLKnZMftk6ZtNhE-W2eqU6yqkQXPMuAZb194iJs/s320/P1040147.JPG" width="320px" /></a></div><div style="text-align: justify;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-17o6ACGQYBZ0F-MojupaxmzA-WHar-i7cKMDXvsXB6H9Bu9GuBMeNcjqj6n1P1rxFceqDltCLsafpJ17cZdwoSnkX2Gh_W0PWEmwKuHWJEJ36QaOnxGaxSCxNcp68PIMOTQ0r2RqECc/s1600/Last+pc+of+formers.JPG" imageanchor="1" style="clear: left; cssfloat: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240px" px="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-17o6ACGQYBZ0F-MojupaxmzA-WHar-i7cKMDXvsXB6H9Bu9GuBMeNcjqj6n1P1rxFceqDltCLsafpJ17cZdwoSnkX2Gh_W0PWEmwKuHWJEJ36QaOnxGaxSCxNcp68PIMOTQ0r2RqECc/s320/Last+pc+of+formers.JPG" width="320px" /></a></div><div style="border-bottom: medium none; border-left: medium none; border-right: medium none; border-top: medium none; text-align: justify;">After gluing the triangular strips, came the motor mount. Because the plan recommended front mount and using brushed motor, I chose otherwise to use brushless setup but ran into problems. The wires would rub onto the bell casing and this is bad. This problem kept me thinking for one week. Finally I opted for one motor and reversed the shaft so that the motor wires exited from its rear and wires would never rubbed onto the bell housing. Its no joke when motor wires rubbed while the glider is up in the air and when you will see smoke churning out of the nose, you know you are in big trouble.</div><div style="text-align: justify;"><br />
</div><div style="text-align: justify;">Some pics of the motor mount and fuse clearance.</div><div style="text-align: justify;"><br />
</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgJydubq4kuxFNbPhpqWhL5sych8ejBoOKHyEN_JiyC6lKlkaDM3sMuQ9kvkYCjV-rSSIMDn2CnFEK0UUlVxeJhoZhp877BaQlYX1-IXbB9W4KS7Uvgr1h9iT7UqxYp0QjOA_vJoZHbzy8/s1600/Motor+Mount+I.JPG" imageanchor="1" style="clear: left; cssfloat: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240px" px="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgJydubq4kuxFNbPhpqWhL5sych8ejBoOKHyEN_JiyC6lKlkaDM3sMuQ9kvkYCjV-rSSIMDn2CnFEK0UUlVxeJhoZhp877BaQlYX1-IXbB9W4KS7Uvgr1h9iT7UqxYp0QjOA_vJoZHbzy8/s320/Motor+Mount+I.JPG" width="320px" /></a></div><div style="text-align: justify;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUI-AlX3w_Ht81qk1BMoNxoD0b9OwAj7099_B5tuvElYSRVGkBbOJpxg3ZXH9feExeS_J7yu_cu8EWi1CZwVxZN8z8FEYeHEmUBgh-iRE0kFSzecb1Fx88kWdSz3OI-uufs5cikDv2CeA/s1600/Motor+dry+fit.JPG" imageanchor="1" style="clear: right; cssfloat: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="240px" px="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUI-AlX3w_Ht81qk1BMoNxoD0b9OwAj7099_B5tuvElYSRVGkBbOJpxg3ZXH9feExeS_J7yu_cu8EWi1CZwVxZN8z8FEYeHEmUBgh-iRE0kFSzecb1Fx88kWdSz3OI-uufs5cikDv2CeA/s320/Motor+dry+fit.JPG" width="320px" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRT4GiVSkkheBMVGtbqWUCUCm4Kt_ZQCLWLHDmozhyphenhyphenQ0aKnb6csFylDOtPt0tkBFSoZC2zWJv8JcUVqNJfbUfYVEhV3WzijhpOj2JPh9YzXKZ-yTM2d6SUvuXzFg1xkkBl6vepxZI78Ao/s1600/Motor+Nose+Iv.JPG" imageanchor="1" style="clear: right; cssfloat: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="240px" px="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRT4GiVSkkheBMVGtbqWUCUCm4Kt_ZQCLWLHDmozhyphenhyphenQ0aKnb6csFylDOtPt0tkBFSoZC2zWJv8JcUVqNJfbUfYVEhV3WzijhpOj2JPh9YzXKZ-yTM2d6SUvuXzFg1xkkBl6vepxZI78Ao/s320/Motor+Nose+Iv.JPG" width="320px" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitnB_IcGB_EyomTa24DIZZs-aCfBEgUadsZJFfiwlYLCaOq4tHIaiWLjzM0Z5poUw5rPQ70sPHDNIKf7adWATD7EcEWFdlSMOyO2dAGmYnKoQCaaD4tVIYttnFy9ZZl8JhbS2qS3ccULo/s1600/Motor+nose+III.JPG" imageanchor="1" style="clear: left; cssfloat: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240px" px="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitnB_IcGB_EyomTa24DIZZs-aCfBEgUadsZJFfiwlYLCaOq4tHIaiWLjzM0Z5poUw5rPQ70sPHDNIKf7adWATD7EcEWFdlSMOyO2dAGmYnKoQCaaD4tVIYttnFy9ZZl8JhbS2qS3ccULo/s320/Motor+nose+III.JPG" width="320px" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9wJ99lNdrbqRz9tVjTX7jhLrstB5nbs5rp3ATdK6ZhW1IX7ofyZ3G-y_vERINLgqy-iK7sW2uwXWGZ7RVLcSHuLP4gF7asESgCx1KJ3CSF29yMZTBAssrkG170PZRIw0XeZPOnMsX1RE/s1600/P1040114.JPG" imageanchor="1" style="clear: left; cssfloat: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240px" j8="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9wJ99lNdrbqRz9tVjTX7jhLrstB5nbs5rp3ATdK6ZhW1IX7ofyZ3G-y_vERINLgqy-iK7sW2uwXWGZ7RVLcSHuLP4gF7asESgCx1KJ3CSF29yMZTBAssrkG170PZRIw0XeZPOnMsX1RE/s320/P1040114.JPG" width="320px" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
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</div><div class="separator" style="clear: both; text-align: center;"></div><table cellpadding="0" cellspacing="0" class="tr-caption-container" style="float: left; margin-right: 1em; text-align: left;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9RY6KzFmXHxo9trkH-WT4__nTPZ1D1b06Wlm_M1xcuQEuMWrPbVxe6i-ZLZ7vz1CPWkoU28PSEqI7aBIDJMhWpy8KV17nB_if1kxVs3mvtvKWBYPlMI6qxS7W73861bJ1kjxs0gEfF7g/s1600/P1040106.JPG" imageanchor="1" style="clear: left; cssfloat: left; margin-bottom: 1em; margin-left: auto; margin-right: auto;"><img border="0" height="240px" j8="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9RY6KzFmXHxo9trkH-WT4__nTPZ1D1b06Wlm_M1xcuQEuMWrPbVxe6i-ZLZ7vz1CPWkoU28PSEqI7aBIDJMhWpy8KV17nB_if1kxVs3mvtvKWBYPlMI6qxS7W73861bJ1kjxs0gEfF7g/s320/P1040106.JPG" width="320px" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Before reversal of motor shaft</td></tr>
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<table cellpadding="0" cellspacing="0" class="tr-caption-container" style="float: right; margin-left: 1em; text-align: right;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiahIeyGDEtnh8yBOdiv5oUOeuemkhTEqICtBX5iJYwSFeE_UU-W-8NN_OUiJxzpsGNSr9QKxIRWLJXrZnvbGr5UNG0Ewk87djNgmY2fOMP0YmZVZ9qJqU89WCLaMFk1eEUolugk2CknZU/s1600/P1040127.JPG" imageanchor="1" style="clear: right; cssfloat: right; margin-bottom: 1em; margin-left: auto; margin-right: auto;"><img border="0" height="150px" j8="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiahIeyGDEtnh8yBOdiv5oUOeuemkhTEqICtBX5iJYwSFeE_UU-W-8NN_OUiJxzpsGNSr9QKxIRWLJXrZnvbGr5UNG0Ewk87djNgmY2fOMP0YmZVZ9qJqU89WCLaMFk1eEUolugk2CknZU/s200/P1040127.JPG" width="200px" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">After reversing motor shaft</td></tr>
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<div class="separator" style="clear: both; text-align: center;"></div><div style="text-align: justify;">The author recommends sticking the servos to the sides of the fuselarge. I was concerned the tape might give way over time so I made servo mounts for the HS65</div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh7RMZyWJ6de72Y3mL6AlZl3tp-jrhRB9XazyHvDmiZe00Ksr8KTVtE8qNYz3b5d48PhTm2G-wyv-X7oZot9L684qQ6c64eqRuTINu6wYGgfQDUNbzC4H4b3V9vfVlRfLQo5TBdjpsUamw/s1600/P1040151.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240px" j8="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh7RMZyWJ6de72Y3mL6AlZl3tp-jrhRB9XazyHvDmiZe00Ksr8KTVtE8qNYz3b5d48PhTm2G-wyv-X7oZot9L684qQ6c64eqRuTINu6wYGgfQDUNbzC4H4b3V9vfVlRfLQo5TBdjpsUamw/s320/P1040151.JPG" width="320px" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Proper mount for the servos</td></tr>
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2VU-rKv8hyphenhyphencSJkqK7Le-DLdeIC4AZiYVlhW2XkVhONvnySon-2IAiWkvhCZ5BwLH_mLERXdlUnRTUAW8_x-4GXy7vHd15rbssYjbkzADV0Sp9DNd6dM67CIawZOP-EoF1Ocl99V1tTkg/s1600/P1040053.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240px" j8="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2VU-rKv8hyphenhyphencSJkqK7Le-DLdeIC4AZiYVlhW2XkVhONvnySon-2IAiWkvhCZ5BwLH_mLERXdlUnRTUAW8_x-4GXy7vHd15rbssYjbkzADV0Sp9DNd6dM67CIawZOP-EoF1Ocl99V1tTkg/s320/P1040053.JPG" width="320px" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Vertical fin with build in screws for horizontal stab</td></tr>
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj825ZYgu0JmRzuG3kfPs8Us-VaFP0Catqs05uuVEsa1caamtkQ4pKQV8V8RHCWTLOPxpVXu1kSck-Iuw0A5_fIPahw9s_S0wjWhQ7Gu93PYYXBgVbEuDJ1W6IlnMf5h7Fr5Xa7muAVjn8/s1600/P1040156.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240px" j8="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj825ZYgu0JmRzuG3kfPs8Us-VaFP0Catqs05uuVEsa1caamtkQ4pKQV8V8RHCWTLOPxpVXu1kSck-Iuw0A5_fIPahw9s_S0wjWhQ7Gu93PYYXBgVbEuDJ1W6IlnMf5h7Fr5Xa7muAVjn8/s320/P1040156.JPG" width="320px" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Drilling the wing to accept the fixing bolt, very critical</td></tr>
</tbody></table></div><div class="separator" style="clear: both; text-align: left;">Sanding the fuselarge to the right shape The deepest indentation shows how much of material needs to be remove<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiGZvZSznMcAjYfocV9nRMw7ph-Ti-gtLRa3x5rqjXuX0QagiqcLis9daf-LxrjdFidv1cAe1HptwB_kkVEVlAh-vss9mtWpO4m1OZpnfG_cl8_2k2557i58Ti-ICJr4XVSn1eej4sglNQ/s1600/P1040162.JPG" imageanchor="1" style="clear: left; cssfloat: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240px" j8="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiGZvZSznMcAjYfocV9nRMw7ph-Ti-gtLRa3x5rqjXuX0QagiqcLis9daf-LxrjdFidv1cAe1HptwB_kkVEVlAh-vss9mtWpO4m1OZpnfG_cl8_2k2557i58Ti-ICJr4XVSn1eej4sglNQ/s320/P1040162.JPG" width="320px" /></a>d. </div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPhv3eVUm15771ldHxs7hQRJnmBe4GQ5IxBWmxWut7q45x0NhvTcYfM82Q1jvInvzKN5Q1bQFSmydiSViwiw_3p4c-pn50LK8oUdJrShnXFe8LKoi668MGLW-IfsqMHXoqKnVSSx9RMMc/s1600/P1040164.JPG" imageanchor="1" style="clear: left; cssfloat: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240px" j8="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPhv3eVUm15771ldHxs7hQRJnmBe4GQ5IxBWmxWut7q45x0NhvTcYfM82Q1jvInvzKN5Q1bQFSmydiSViwiw_3p4c-pn50LK8oUdJrShnXFe8LKoi668MGLW-IfsqMHXoqKnVSSx9RMMc/s320/P1040164.JPG" width="320px" /></a></div><div style="text-align: justify;"><br />
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEZV4dBkqaTVdjESoAA5MLVoqUU10cNwXMLL9nsdl_9POn50e7YQblg-YEFopBUnqLBsgF-wPRzw_AHqZUcLvBO6AtWW94brtt0yVoScqG6m6PpeV4rWWLzUi0LW2ZIGSvcjCiDFNrh14/s1600/P1030048.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240px" px="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEZV4dBkqaTVdjESoAA5MLVoqUU10cNwXMLL9nsdl_9POn50e7YQblg-YEFopBUnqLBsgF-wPRzw_AHqZUcLvBO6AtWW94brtt0yVoScqG6m6PpeV4rWWLzUi0LW2ZIGSvcjCiDFNrh14/s320/P1030048.jpg" width="320px" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">The completed Guppy</td></tr>
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Above shows the completed model. Not really, there is one more thing, the canopy, a big headache. I tried the boiling method, its really hopeless, the bottle shrink in all the thin places and the thicker areas did not shape at all. Moreover the bottle has to be quite big to fit the mould. I gave up using this method and went for the pro approach. The vacuum forming method. Here is a video of it.<br />
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<a href="http://www.youtube.com/watch?v=aCV-yyqzGF8">http://www.youtube.com/watch?v=aCV-yyqzGF8</a> (view in HD)<br />
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</div><div class="separator" style="clear: both; text-align: center;"><iframe allowfullscreen='allowfullscreen' webkitallowfullscreen='webkitallowfullscreen' mozallowfullscreen='mozallowfullscreen' width='320' height='266' src='https://www.blogger.com/video.g?token=AD6v5dxTmGTIyrUzKSoANPLi-cnU1CKsLVznTVuOkLsT-DD_KjXAsDy65BhJTDA1cMyvUrbRTZe54uSkV-s1iP8Ung' class='b-hbp-video b-uploaded' frameborder='0'></iframe></div><div style="text-align: justify;">One try is all it takes, one perfect canopy. I covered the wings with Ultracote and body with Litecote. Ultracote is great, sticks well and shrinks perfect but its a bit heavy. With all the electronic inside, I weigh the aircraft and it tipped the scale at 540grams. Not too bad for a 3s 1050mah setup. I chose a 9x4" folding prop for a fast climb rate but not that fast to bloot the Lipo. </div><div style="text-align: justify;"><br />
</div><div style="text-align: justify;">The completed aircraft.</div><div style="text-align: justify;"><br />
</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMezMoy__6vUWwpOlEkuhO5YVm-rUma6BVCNvLlxrUZcnPiTOjUpsdycKicjrVxRUWVyX8caUHkkeEwD6D1ZKYXv2QddTzn09YBvCI4EFB_P_B4rejXCHTva4UHdotyR3rqpa20Pth2Y0/s1600/P1030099.JPG" imageanchor="1" style="clear: left; cssfloat: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" ex="true" height="240px" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMezMoy__6vUWwpOlEkuhO5YVm-rUma6BVCNvLlxrUZcnPiTOjUpsdycKicjrVxRUWVyX8caUHkkeEwD6D1ZKYXv2QddTzn09YBvCI4EFB_P_B4rejXCHTva4UHdotyR3rqpa20Pth2Y0/s320/P1030099.JPG" width="320px" /></a></div><div style="text-align: justify;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgRpnDEYbmMW-dxyMP0BQT24bscEZW1uJQX1wWSUM8aEgzsCkvybTQh2WKgS0sYxlu7e_Wb1ufViqqNogGXNnbEiRrzztcDjbrCbIqdqN1pzVbNDE5lfZZ3W7dweL4EbV-m2j1KApsXMXM/s1600/P1030097.JPG" imageanchor="1" style="clear: right; cssfloat: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" ex="true" height="240px" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgRpnDEYbmMW-dxyMP0BQT24bscEZW1uJQX1wWSUM8aEgzsCkvybTQh2WKgS0sYxlu7e_Wb1ufViqqNogGXNnbEiRrzztcDjbrCbIqdqN1pzVbNDE5lfZZ3W7dweL4EbV-m2j1KApsXMXM/s320/P1030097.JPG" width="320px" /></a></div><div style="text-align: justify;"><br />
</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikULua8MNJdEwpZSYq3f5OZuASmDp3whjL1DWPRGPg3CabUQea3TvfNFOeByXuxU8pM6SOB09htF5dYuPKRuDr8lmeXnBVW3ZtiOoSlTiellz6zz0hgJGrziFwPIgEhlSv6g8KmqGECJo/s1600/P1030103.JPG" imageanchor="1" style="clear: left; cssfloat: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" ex="true" height="240px" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikULua8MNJdEwpZSYq3f5OZuASmDp3whjL1DWPRGPg3CabUQea3TvfNFOeByXuxU8pM6SOB09htF5dYuPKRuDr8lmeXnBVW3ZtiOoSlTiellz6zz0hgJGrziFwPIgEhlSv6g8KmqGECJo/s320/P1030103.JPG" width="320px" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3mUvPtlDDj9bBTwnw02gwIFn1CvG_uGMEp-pEn-Y_SYRmQeXEmEmSKEyKOFo_kW1LguOBMWrSnQ2ncUg_PMwuIvnELr-w7LD7JS-u1d_QkchfNkHRTfVYBWSVc8wQH-EapFdOYNGw4hA/s1600/DSC_0923.JPG" imageanchor="1" style="clear: right; cssfloat: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="211px" j8="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3mUvPtlDDj9bBTwnw02gwIFn1CvG_uGMEp-pEn-Y_SYRmQeXEmEmSKEyKOFo_kW1LguOBMWrSnQ2ncUg_PMwuIvnELr-w7LD7JS-u1d_QkchfNkHRTfVYBWSVc8wQH-EapFdOYNGw4hA/s320/DSC_0923.JPG" width="320px" /></a></div><div style="text-align: justify;"><br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgie4coOes15QB83PwVoOHAJdeJDld8HR9O62TdLIZXm6Ekh3GzCmTmAu34DpR2nvIx73SwoprCeC32da2WWVyZ57Ta2i-aOXXmfKs9h4ElzYi0IxcrKrkwdT83r2-v7LDFsuBhERK1yY/s1600/DSC_0926.JPG" imageanchor="1" style="clear: right; cssfloat: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="212px" j8="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgie4coOes15QB83PwVoOHAJdeJDld8HR9O62TdLIZXm6Ekh3GzCmTmAu34DpR2nvIx73SwoprCeC32da2WWVyZ57Ta2i-aOXXmfKs9h4ElzYi0IxcrKrkwdT83r2-v7LDFsuBhERK1yY/s320/DSC_0926.JPG" width="320px" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDBeTfKI7mwisPabT-uf_PlYvEtwfVq8n6414leXAVQYH4VS9xJ06Bah-1A4gZItstKm3Af8Yvd61ye07N6Xz9i848ITVokB8SPlOrKbgjLhV31GcNpyeL1rA2tUudcKp0IumARODm1rk/s1600/DSC_0924.JPG" imageanchor="1" style="clear: left; cssfloat: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="212px" j8="true" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDBeTfKI7mwisPabT-uf_PlYvEtwfVq8n6414leXAVQYH4VS9xJ06Bah-1A4gZItstKm3Af8Yvd61ye07N6Xz9i848ITVokB8SPlOrKbgjLhV31GcNpyeL1rA2tUudcKp0IumARODm1rk/s320/DSC_0924.JPG" width="320px" /></a></div><div align="left"></div>Maiden was great with a slight tail heavy, I slightly relocate the battery and it flies great, 70 degree climb is easy with the powerful motor and 3s setup, descend rate is very slow, flight time is around 30 minutes on one discharge. 5 times full throttle is the max I can achieve for a full one minute climb to almost a small visible dot. Landing is very precise as the rate of descend is slow and graceful. </div><div style="text-align: justify;"><br />
</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIJdEIAVde-JXsr4B2RpX9QqSWtVAvAMF_a_EJajjdG7ZL0itgS5Q1V-x0fpprXYLYWnNYtujd6cLwVMHnGO6cCw1Mp9bxESz-fuLYjSn6TiGEpHFuNeVCAryCy0bXp0jyx2EbBmh-TV8/s1600/8e5da11b.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" ex="true" height="426px" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIJdEIAVde-JXsr4B2RpX9QqSWtVAvAMF_a_EJajjdG7ZL0itgS5Q1V-x0fpprXYLYWnNYtujd6cLwVMHnGO6cCw1Mp9bxESz-fuLYjSn6TiGEpHFuNeVCAryCy0bXp0jyx2EbBmh-TV8/s640/8e5da11b.jpg" width="640px" /></a></div><div style="text-align: justify;"> Seventy degree climb, up.....up....up</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrFARyCtSGCVECjHYiNR0feIbyuPlSbpMrF3g40HEMywrQ_ohWjUizY2qCADn6AkprTw4YnSDDSRjjMpnAvoNSnse_cX8M-Ay327-gsDPiH8qLd2cFqbR3rGrxC4kc64BiWwYP4H0jLtA/s1600/04ab9d93.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" ex="true" height="426px" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrFARyCtSGCVECjHYiNR0feIbyuPlSbpMrF3g40HEMywrQ_ohWjUizY2qCADn6AkprTw4YnSDDSRjjMpnAvoNSnse_cX8M-Ay327-gsDPiH8qLd2cFqbR3rGrxC4kc64BiWwYP4H0jLtA/s640/04ab9d93.jpg" width="640px" /></a></div><div style="text-align: justify;"> Slow descend hunting for thermal</div><div class="separator" style="border-bottom: medium none; border-left: medium none; border-right: medium none; border-top: medium none; clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgZyqvjKxifg-WoC4cwNqMEC2QDjczuAvsHPOVb89UcrmOqlj56e2H4d8j0PL2kc26WfaeOAj-TEGfw6oJSRAugg4p0ziY76rIhESSc6YhV9jP4wRf31zPfNykIWqesTmmfVYFms662vrk/s1600/eb326612.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" ex="true" height="426px" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgZyqvjKxifg-WoC4cwNqMEC2QDjczuAvsHPOVb89UcrmOqlj56e2H4d8j0PL2kc26WfaeOAj-TEGfw6oJSRAugg4p0ziY76rIhESSc6YhV9jP4wRf31zPfNykIWqesTmmfVYFms662vrk/s640/eb326612.jpg" width="640px" /></a></div><div class="separator" style="clear: both; text-align: center;"></div><div style="border-bottom: medium none; border-left: medium none; border-right: medium none; border-top: medium none; text-align: justify;"> Power up and orientate for landing<br />
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Video of Guppy in flight <a href="http://www.youtube.com/watch?v=xq1Sm6FQMvI">http://www.youtube.com/watch?v=xq1Sm6FQMvI</a></div><img height="72px" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgxdDwIdh9RUwKPsGtQy-jSrS8TP0iycfsKkOqst_DXoCCGpQ0yvDLttDFVlhU__eq2Y2DiCut2HOtP8V0dvEzyINlK41nD5q9pgPLmMpMjidyEYCwAXMAOM5Hu7w56uujns0V8kKSu0ws/s200/P1040093.JPG" style="filter: alpha(opacity=30); left: 167px; mozopacity: 0.3; opacity: 0.3; position: absolute; top: 380px; visibility: hidden;" width="96px" /> <br />
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<div align="left" class="separator" style="border-bottom: medium none; border-left: medium none; border-right: medium none; border-top: medium none; clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPKb78ds9fR-DLjkZuPuXxeN_cTM1XqPAouP3LaRb7Kak2IElL5_GPkAFL-UF9KOgaUxVWZDsRm89f6R3jp8c4GVdC40OejZP8-V4SBfQY5W2PgwDM3fOUT17x3jwK6sSEGbcNEKxCsLU/s1600/Wings+on+plan.JPG" imageanchor="1" style="clear: right; cssfloat: right; float: right; margin-bottom: 1em; margin-left: 1em;"></a></div><div class="separator" style="border-bottom: medium none; border-left: medium none; border-right: medium none; border-top: medium none; clear: both; text-align: left;"></div>Flybywire http://www.blogger.com/profile/12033050948969565462noreply@blogger.com0