Hard Lessons Learned While Building A Solar RC Plane

September 9, 2024 by Maya Posch 17 Comments

Although not the first to try and build a DIY solar-powered remote control airplane, [ProjectAir]’s recent attempt is the most significant one in recent memory. It follows [rctestflight]’s multi-year saga with its v4 revision in 2019, as well as 2022’s rather big one by [Bearospace]. With so many examples to look at, building a solar-powered RC airplane in 2024 should be a snap, surely?

The first handicap was that [ProjectAir] is based in the UK, which means dealing with the famously sunny weather in those regions. The next issue was that the expensive, 20% efficient solar panels are exceedingly fragile, so the hope was that hot-gluing them to the foam of the airplane would keep them safe, even in the case of a crash. During the first test flights they quickly found that although the airplane few fairly well, the moment the sun vanished behind another cloud, the airplane would quite literally fall out of the sky, damaging some cells in the process.

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Stretching The Flight Time On A Compressed Air Plane

October 15, 2023 by Danie Conradie 23 Comments

[Tom Stanton] has been experimenting with compressed air motors on model aircraft for a good few years, but keeping them aloft (and intact) for more than a few seconds has proven a tough nut to crack. His latest design represents a breakthrough — pulling off an impressive 1 minute and 26 seconds flight on 4 liters of compressed air.

The model incorporates an enhanced engine design featuring an expanding seal on the piston, a concept inspired by the old Air Hogs toy plane. For the airframe, he constructed lightweight wings using 3D printed ABS ribs on a carbon spar and reinforcing rods, all of which were wrapped in heat shrink film. Additionally, [Tom] incorporated a thin balsa former along the leading edge of the wing to help maintain its shape. The fuselage is also composed of a carbon fiber tube, and is outfitted with printed fittings to install the wings, V-tail, RC electronics, and soda/air bottles. A hollow nylon bolt holds the two bottles together end-to-end while allowing the motor to be screwed directly onto the front bottle. To conserve weight, each of the two V-tail control surfaces are actuated by single cables linked to servos, with piano wire torsion springs in the hinges to maintain tension

Despite successful flights, [Tom]’s trials were not without challenges. One crash threatened severe damage to his airframe, but thanks to a central 3D printed bracket that absorbed most of the impact, total destruction was avoided. Similarly, a printed shaft saved his expensive carbon fiber propeller from being damaged during multiple landings, an outcome that led [Tom] to devise a readily replaceable consumable connector.

A second video after the break offers a behind-the-scenes insights into this project including some fascinating technical details. For more on this project’s history, take a look at the initial diaphragm engines and his attempts to make them fly.

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Building A Giant Remote Controlled Model Airbus A380 In A Year

January 8, 2023 by Maya Posch 21 Comments

A year ago [Ramy RC] set out on a momentous challenge: to build a 1:21 scale Airbus A380-800 RC model with functional engines, landing gear and all other details. Recently he finished the project and published a video with a summary of the whole build process (also linked below). The full video series can be found on the Ramy RC channel. The final RC airplane came out at a massive wingspan of 3.9 meters (12.7′), a length of 3.6 meters (11.8′) and a weight of 25 kg. This weight is carried by the full landing gear of multiple bogeys that can retract much like on the real airplane.

A range of materials were used for the body, including carbon fiber and wood, with each part carefully modeled with CAD software and 3D-printed or cut on a CNC cutter. Four ducted fans provide the propulsive power that lift this enormous model airplane into the skies, which is the only part where the noise profile doesn’t quite match that of the real A380. Even so, seeing the airplane taxing, taking off and flying through the skies makes you look twice to realize that it is in fact a scale model and not a real Emirates A380-800, also courtesy of the excruciating amount of detail to the model’s final look, down from the logos to the silver-grey lines.

We’re also quite convinced that the maiden flight of such an exquisite model has to be one of the most terrifying experiences imaginable.

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Power Tool Hack Takes A New Angle On RC Power Plants

October 5, 2022 by Ryan Flowers 25 Comments

For eons, hacker minded people have looked at various items their pile of stuff, came up with an outlandish idea and thought “I wonder if it would work?” Some of us stop there, convincing ourselves that it’s a bad idea that could never work. Others of us such as [Peter Sripol] are well known for not just having those thoughts, but for having the grit to explore them to their impractical limit, such as is shown in the video below the break.

Peter begins by adapting a model airplane propeller to his 9500 RPM battery powered grinder, and then checks thrust with different propellers to see which seemed most efficient. Then [Peter] did what any aerospace engineer out of their right mind would do: He had his brother design the resulting aircraft, which was inspired by an obscure German WWII asymmetric aircraft design.

Did it fly? It did, and you can see a couple of iterations of it tooling around in the video. But what happened next was equally interesting: First, a grinder powered single bladed helicopter and its subsequent hilarious failure, and its slightly more successful successor.

We’ve of course covered many angle grinder hacks, such as this fixture for perfect cuts (something notoriously difficult to do with a handheld grinder), but this is the first time we’ve seen an angle grinder fly out of more than frustration. Do you have your own angle grinder hack to spin our way? Be sure to let the Tip Line know!

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World’s Biggest Foam RC Plane Takes To The Skies, But Only Barely!

July 18, 2022 by Ryan Flowers 17 Comments

What do you do when you have a whole warehouse sized facility and an industrial sized CNC foam cutter? Clearly, the only choice is to build giant RC aircraft, and that’s exactly what the folks at [FliteTest] teamed up with the illustrious [Peter Sripol] to accomplish. Did it work? Yes. Did it work well? We’ll let you be the judge after taking a gander at the video below the break.

[Peter Sripol], known for building manned ultralight electric aircraft from foam, was roped in as the designer of the aircraft. A very light EPS foam is used to cut out the flying surfaces, while a denser green foam board is sourced from the local home building store to construct the fuselage.

The build is anything but ordinary, and kids are involved in the construction, although the video doesn’t elaborate on it very much. You can see evidence of their excitement in the graffiti on the wings and fuselage- surely a huge success on that front! As for flying? Four large motors provide locomotion, and it’s barely enough to keep the beast flying. A mishap with the Center of Gravity demands a last minute design change which renders the rudder almost useless. But, it does fly, and it is a great step toward the next iteration. Just like every good hack!

If you want to see a manned foam electric aircraft, check out [Peter Sripol]’s DIY Electric Ultralight MK4.

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Electric “Radial” RC Aircraft Motor

September 19, 2021 by Danie Conradie 23 Comments

For a long time radial aircraft engines, with their distinctive cylinder housings arranged in a circle, were a common sight on aircraft. As an experiment, [KendinYap], wanted to see if he could combine 3 small DC motors into a usable RC aircraft motor, effectively creating an electric radial engine.

The assembly consists of three “180” type brushed DC motors, mounted radially in a 3D printed casing. A 3D printed conical gear is attached to each motor shaft, which drives a single output gear and shaft mounted in the center with two bearings. The gear ratio is 3:1. A variety of propellers can be mounted using 3D printed adaptors. As a baseline, [KendinYap] tested a single motor on a scale with a 4.25-inch propeller on a scale, which produced 170 g of thrust at 21500 RPM. Once integrated into the engine housing, the three motors produced 490 g of thrust at 5700 RPM, with a larger propeller. Three independent motors and propellers should theoretically provide 510 g of thrust, so there are some mechanical losses when combining 3 of them in a single assembly. However, it should still be capable of powering a small RC plane. It’s also not impossible that a different propeller could yield better results.

While there is no doubt that it’s no match for a brushless RC motor, testing random ideas just to see if it’s possible is usually fun and an excellent learning experience. We’ve seen some crazy flyable RC power plants, including a cordless drill, a squirrel-cage blower, and a leaf blower.

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Magnus-Effect RC Aircraft Is A Lot Harder Than It Looks

August 5, 2021 by Danie Conradie 13 Comments

Conventional airfoil wings have come out on top for getting flying machines airborne over the last century, but there were a few other interesting designs that have come and gone. One of these is the Magnus effect plane, which makes use of the lift produced by a spinning cylinder. [James Whomsley] from [Project Air] decided to build one as a side project, but it ended up being a lot more challenging than what he initially suspected. (Video, embedded below.)

The Magnus effect achieved a bit of viral fame a few years when [How Ridiculous] dropped a basketball down a dam wall with some backspin. [James] T-shaped Magnus effect plane has a pair of spinning cylinders at the top to create lift, driven by a brushless motor using a belt. A second brushless motor with a propeller is on the center carbon fiber tube provides forward thrust, and a rudder provides yaw control. The battery is attached to the bottom of the tub for stability.

The very first flight looked very promising, but [James] quickly ran into a series of problems related to center of gravity, power, pitch control, and drag. After iterations of the build-crash-rebuild cycle, he ended up with larger motors and rudder, shorter “wings”, and a higher thrust motor position. This resulted in a craft still only marginally controllable, but stayed in the air for quite a while. Since the intention was never to turn it into a long-term project, James] called it a success to avoid more yak shaving, and continue work on his airboat and rocketplane.

If you are interested in building one of your own, he put all the findings of his experimentation in a short report. For more inspiration, check out the other Magnus effect plane we covered that used KFC buckets for the wings.

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