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Showing posts from December, 2014

CNC Drilling and Cutting Fuselage Boom

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Building The EMG-6 (CNC Drilling and Cutting Fuselage Boom)  We've recently started working on the kits for the fuselage boom. The majority of the fuselage boom is built from 2024 T3 aluminum .040" thick and all the components are CNC cut on the CNC router and bent using the CNC press brake. Using the CNC router to cut sheet metal and drill it is not the most efficient method, but provides us a cost-effective method to produce the parts with CNC accuracy. There are a total of 5 different sheet-metal patterns that produce parts from 4 x 8 sheets. Each sheet has from between 6 to 20 different toolpaths. In the video which is all time lapse photography it happens quickly but in reality each sheet requires between 3 to 5 hours of drilling and cutting time. The sequence of events requires drilling 4 locations on the sheet that gets screwed to the MDF tabletop. Then the drilling proceeds to drill all of the locations on the sheet that are required to hold down small parts or hold …

53-10-09-72 Passenger Rudder Pedal Tube Installation (Video)

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Building The EMG-6 (53-10-09-72 Passenger Rudder Pedal Tube Installation)  In this episode of building the EMG_6 We install the Passenger Rudder Pedal support tube for the fuselage frame






53-10-09-71 Seat To Gear Box Tube (Video)

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Building The EMG-6 (53-10-09-71 Seat To Gear Box Tube)  In this episode of building the EMG_6 We install the Seat To Gear Box tube for the fuselage frame




53-10-09.100 Brake Mount Tube (Video)

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Building The EMG-6 (53-10-09.100 Brake Mount Tube) 
In this episode of building the EMG_6 We install the brake mount tube for the fuselage frame


51-60-10 Bushing Holder (Video)

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Building The EMG-6 (51-60-10 Bushing Holder)  In this episode of building the EMG_6 we go behind the scenes to see how we manufacture one of the EMG-6 parts from start to finish. Follow along as we design and manufacture (P/N 51-60-10 bushing holder) using solid works and solid cam software and then cut and machine this integral part on the EMG-6


GT 500 Tow Plane Flight Test Excerpt

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GT 500 Tow Plane Flight Test Excerpt  This is the 1st 10 minutes of an hour-long flight test on the GT500 tow plane that we have set up to be used for towing the EMG-6 electric motor glider.


EMG 6 Flight on Google Earth Overlay

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EMG 6 Flight on Google Earth Overlay  This is test flight number 55 and 56 from a little different perspective. We have overlaid the flight video with the .kml  file from the Ascent flight data recorder output to Google earth.

EMG-6 / GT-500 Tow System Testing Tow release handle

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EMG-6 / GT-500 Tow System Testing Tow release handle  In this video we test the second-generation tow release handle on the GT-500 Tow plane.

EMG-6 / GT-500 Tow System Testing

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EMG-6 / GT-500 Tow System Testing  Another video in the series Building the EMG-6. In this episode we experience a design failure in GT-500 Tow Plane during Tow Release testing.

53-10-05A Landing Gear Box Assembly (Video)

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53-10-05A Landing Gear Box Assembly This is another episode in the Building The EMG-6 Series. In this episode we show how to attach the landing Gear Box to the rest of the fuselage frame.

December 2014 Progress Blog

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