Composite Tail Construction

[Brian Jackson]

Hello all.
I would like to learn techniques for working with foam and composite materials in an attempt to design a tail for my upcoming gyrobee project. What web sites (if any) would anyone recommend for educational purposes? Thanks.

Regards,
Brian Jackson

[Jon B]

It is actually pretty easy to do, what I've learned is from a friend who is building a Cozy Mark IV. You might find someone familiar with composites at you local EAA

Good luck

[nsheryka]

Its actually very easy.. just takes a little getting used to. I will look for some good websites and get back to you with them.

I am going to be using a slightly modified Watson tail, built from scratch. After talking to grobee flyers with the watson tail.. they all seem to say it is great, however they wish it had a little more rudder athority. I plan on adding about a square foot of surface area to the back of the rudder (thanks doug riley).

[rfonseca]

Two good books are:

Understanding Aircraft Composite Construction by Zeke Smith. Aeronaut Press, Napa, CAlifornia, and Composite Construction for homebuilt Aircraft by Jack Lambie, Aviation Publishers Book.

There is also a large page booklet that was published by Burt Rutan a few years ago and that became the bible of the trade. I understand that the above two books include everything in the Rutan publication plus more. Nevertheless, I could dig it out if you wish.

[smckenna]

Another good way to get started is to sign up for one of the EAA SportAir Workshops, if one will be held within traveling distance. I went to one here in Denver, a couple of years back, & found that it was worthwhile. You get a bit of class work & some hands-on time. Not a complete training course, but it does give you the basics and a lot more confidence.

Steve

[Dean_Dolph]

Brian, You Do have to be careful when working with the resins/epoxys. Some people have no problem while others have severe allergic reactions. The products available now are safer than in the past but I wouldn't take any chances.

If you have any technical questions that the books don't answer then contact Gary Hunter, the owner of Gary Hunter Composites in Houston TX.

Contact him at: gluegaru@earthlink.net or phone 281-277-7767.

Gary retired from Shell Chemical R&D a couple of years ago and for years served as Shell's answer man on composites. He also has hands on experience as in building a Varieze and serving as crew chief for Bruce Bohannon's Exxon Flying Tiger. He is also presents seminars at EAA events and as a favor to me put one on at the '90 PRA convention in Hearne TX. I've sent gyro several people his way and the feed back has been that he was very helpful.

[Brian Jackson]

Thank you everyone. And Dean, I will take that to heart. I was considering doing a wooden substrate with a bidirectional composite overlay. But the more I learn about composite structures the more I realize I don't know. The areas of knowledge I'd like to gain presents itself.

Are composite structures hard to learn? And since the surfaces I was hoping to duplicate are airfoiled, are they difficult to replicate? I've read some about the "hot wire" technique. Is that easy to learn?

Thank you,
Brian Jackson

[Doug Riley]

Brian: The Watson tail plans included with the Gyrobee documentation show you how to build a tested tail set. This unit includes a six sq. ft. airfoil HS; I flew the prototype for a few dozen hours and can testify that the pitch stability is excellent.

To understand the Watson instructions, you'll need the Rutan book; it's available from the mailorder aoircraft supply houses such as Wicks and Aircraft Spruce.

[Brent_Brown]

"hot wire" Is how I do my tails and I used the Rutan book. I use a AL. tube for a spar and th horns and bolts mount to it. this keeps it light and less glass work for the haed points. The information in Rutan book is good and you can make very small test tails to work out the techniques needed to do a good job. At some time I will be all set up for better use for my hanger, but right now I am still working on unpacking and finding my things. The hard part of glassing tails is sanding it smooth.