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Old 04-15-2017, 02:21 PM   #261 (permalink)
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a little build mention

I'll construct the new tail much like a fabric-covered WW-1 aircraft.
*The structural framework is welded 1/2-inch EMT steel tubing.
*Bulkhead stations,formers and stringers will be hand selected cedar fence pickets.
I'm taking the time to cull through hundreds of pickets to isolate the few driest and lightest which can be found in each pallet of material at Home Depot.
It's like buying hundreds of dollars worth of Balsa wood for a few bucks.
This wood will be shaped to the exterior form of the tail and attached to the steel and doped with resin to stabilize it.
Then I've got something to skin.
It's only gonna take forever to complete.

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Old 04-22-2017, 01:12 PM   #262 (permalink)
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stinger shaping up

While the boat tail is still 'open' I'm taking advantage of that.
I clamped batter boards to the tail which project rearwards to define the outside dimensions of the stinger,as you'd do with a concrete foundation.
To carry the stinger inside the boat tail for the trip requires that the stinger be able to break down into 3-pcs which can be assembled at DARKO.
So far,I've got a box-truss fashioned which will be the center 1/3rd of the stinger.
It's cedar picket ripped in half,angle cut,glued,and screwed.I'm using Titebond Exterior glue and drywall screws.
The three sections will marry together to form the 41-inch stinger,using 1/4-20 carriage bolts and palm-nuts.
Aluminum flashing,screwed down with pan-heads will create the skin for each section; attaching as a unit to the boat tail,also with carriage bolts and palm-nuts.
After the stinger is 'proved' with no hitches,I'll close in the 49.5-inch boat tail.
At DARKO,I can attach the faux single wheel under the stinger and test as Spirit-II with a single-wheel trailer (ala BamZipPow's Dark Shadow).
Then yank the phony wheel,testing as Spirit-II with a long-tail.
Followed by dropping the stinger for Spirit-II with truncated boat-tail.
And lastly,dropping the boat-tail,for Spirit sans tail.
We'll have an opportunity to actually see what,if any,the extra length actually does to drag.
This will be the 1st time in 40-years or so that I'll get to experience this sort of thing.
PS,If I were to lose the truck bed and start from scratch,with a custom,boat-tailed box, I could shorten the rig by 54-inches and have basically the same Cd.
here's some pics
Rotten plywood is gone and 3-layers of glass go on where new fairings integrate onto aero shell

Cardboard and tape define the new shape and get 3-layers of glass

At the rear,with lofted surface I get the radii required for Morelli's fluid tail

Batter boards clamp on to define exterior limits of stinger


Center 1/3rd section box truss is created inside the batter boards


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Last edited by aerohead; 04-22-2017 at 02:02 PM.. Reason: add pics
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