PFR - Aerospace Engineering Sciences Senior Design Projects ...

Project Final Report – CUDBF April 30 th , 2009
ASEN 4028: Aerospace Senior Projects
were drying, balsa mounts, which tightly hold the wingtip hinge systems to the main wing, were
shaped to fit into the tips of the main wings. After the wings were dry, the excess balsa was
removed (to include the balsa sheeting covering the motor mount holes) and the wings sanded
while cavities to house the balsa hinge mounts as well as the wiring, nose gear, and centerline
mount were created. While removing excess glue, the glue that inevitably formed around the
nose gear was removed such that the nose gear can rotate unimpeded. The hinge mounts were
glued into place, the wiring fed throughout the wing halves, and the halves joined with the
centerline mounts and nose gear spar securing the two halves together. After this glue dried, the
excess was removed by sanding. Hollows in the wing were then created to house the batteries
and the receiver as well as the circuit board, which together control the aircraft avionics systems.
After the hollows were created, the wiring was fed to the motor locations and into the main
hatch, and battery cables linked to the battery cavity. Holes were cut into the bottom of the wing
to house the elevator servos, which were mounted onto plywood mounts to secure the servos to
the aircraft. Additionally, cavities were cut to house the main landing gear to the bottom of the
airplane. Holes that match the hinge locations on the elevators were drilled into the trailing edge
of the main wing and the elevators attached. The servos were linked to the elevators and the
system tested to ensure functionality.
12.4 Full System Assembly
Figure 110: Full System Assembly
To complete the aircraft assembly, the wingtip wiring was soldered to the wiring running
through the main wing assembly and the hinges screwed into the balsa hinge mounts. The circuit
board which houses the microcontroller and receiver was connected to the wiring within the
aircraft main hatch. The verticals could then be attached to the wingtips. Small cavities were
shaped in both the wingtip and vertical to house two small L shaped aluminum pieces per
vertical. Glue was then applied to the verticals and wingtips and the verticals attached to the
aircraft. Although the vertical sits nicely atop the wingtip airfoil shape, there remained a section
on the bottom of the aircraft where the vertical sits which required a fairing. A small balsa piece
was shaped and attached to maintain an aerodynamic profile at the bottom of the vertical/wingtip
connection. The main landing gear was then glued to the bottom of the aircraft. Once full
128