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Magnus Build thread - TJIRC

Jonathan Wells

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Magnus 60 inch glider from TJIRC.

Prototype build ;)

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Hardware supplied with this Prototype: -
The clevises and carbon horn were not used!
I made the Elevator, aileron and flap horns.
IMG_20200131_225646 - Copy.jpg


Aileron and flap horns.

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Jonathan Wells

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Up first is the elevator horn...
I fitted the tail-plane, marked the required location of the control horn (slightly off center).

Measure 2mm from the wiper and mark!

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Measure 15mm and mark.
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Preparing the tail seat. Remove the flashing from the join/seam (top, bottom, and leading edge) using a ball cutter in your dremel.

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I used a 1.5mm diamond pattern milling cutter to create the slot. I always place my finger directly underneath where i want the slot, this way i know when i'm close to the outer glass/carbon layer.
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Roughen the surface of the horns sides and wipe with isopropyl alcohol. I used 15minute epoxy mixed with West Systems 403. Apply the glue to the horn's holes, bottom and sides. Oh, apply some glue in to the slot cut earlier ;).

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Elevator at full deflection.
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Jonathan Wells

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Installing the elevator servo and tray.

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The same glue mix was used...
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I used 320 grit sandpaper to roughen up the fuse as well as the milling cutter (by hand), I then cleaned with isopropyl alcohol. I applied some glue mix to the fuse and added some nice fillets of the glue mix. Note* The servo just touches the fuse bottom.
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Jonathan Wells

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Installing the G10 Flap control horns and servos...

The servo hatch recess and control surface hinge are perpendicular. Measure 10mm from the outer recess and mark..
I draw a line parallel to the hatch recess, the right hand side of the image is the side of the G10 horn (clevis pin entry).

IMG_20200205_104412.jpg


Transfer to wing top.

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Measure 6mm from the wiper and mark the slot required for the G10 Flap horn.

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Cut through the flap stiffener and though the bottom core layer leaving just the outer glass or carbon layer.

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Next mark and cut the wiper.

IMG_20200205_105735.jpg


Next cut the slot in the top wing skin for the crossover linkage.

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Jonathan Wells

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Ailerons
The servo hatch recess and control surface hinge are perpendicular. Measure 13mm from the outer recess and mark..
I draw a line parallel to the hatch recess, the right hand side of the image is the side of the G10 horn (clevis pin entry). Transfer to the top surface for the crossover linkage.

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G10 Aileron Horn.
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Jonathan Wells

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Installing the Aileron Servos..
Drill and tap a hole as close as possible to the servo arm's hub, for best geometry and to keep everything below the servo cover.
The line indicates the outer side of the servo arm/G10 Horn.

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Clean with isopropyl alcohol..
I used West systems 403 and Z poxy 15min.
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Place some heavy ballast on top of the servo to keep it in place. I use a square and a ruler to make sure the servo and push rod is perfectly perpendicular to the hinge.


Flush Aileron covers are possible...
IMG_20200207_115805.jpg
 
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Wayne

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Comments in the office while watching this video:
Damn!
Wow!
When do we get them?

Did I hear rumor of some planks next?
 

Jonathan Wells

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I think the CG is 87.5mm, I haven't been able to test since the lockdown :(
 
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