Showing posts from 2015

"Spark Testing" Sport Aviation / Experimenter "Technically Speaking" Article November 2015

Sport Aviation / Experimenter magazine "Technically Speaking" November 2015 Article
Our monthly column in Sport Aviation/Experimenter  Magazine for the month of November was an article on spark testing steels.We discuss methods which you can use to identify a piece of 4130 chrome Molly steel from a piece of mild steel or any other type of metal for that matter.

If you're not a member of EAA "you should be".The magazine alone is well worth the annual membership fee.
Link to EAA 
Spark TestingAs with most building trades, (electricians, masons, carpenters,) there are time proven materials and a base line method of performing tasks which become “standard practice”. As an aircraft builder, you soon learn that there is also a time proven set of practices and building materials that are commonplace within the aviation community.
If there is one universal commonality among the countless aircraft types, it is the use of steel within the structure in some form or another. Fr…

EMG-6 Renderings

Renderings We have posted these renderings to help in the visualization of the EMG-6. Click on one of the images to see all of the images in a slide show. These are large format pictures and may take some time to download.

EMG-6 "Shop Notes" December 2015

December "Shop Notes"
"EMG-6 Shop Notes" is a day-to-day accounting of what's going on in the shop with the EMG-6 Electric Motor Glider.
December 18, 2015 TapMatic tapping head.We have finally got the tapping process down to a science.
The final resolution to accomplishing the tapping process was the switch from a cutting system to a roll forming process.
The depth of the tapped hole had to be nearly .75 inches deep .
When cutting into soft material like 6061 T6 aluminum is very easy for the flutes of the To get completely plugged up and then increase the torque on the tap to the point where it snaps off.
We discovered this the hard way experimenting with multiple different tapping methods of using a cutting tap. 
We managed to break 7 taps before we finally resolved the situation.
We even broke one of the roll form taps trying to tap a hole with the original drill size.

57-10-51 Inboard Diagonal Strut Fitting

57-10-51 Inboard Diagonal Strut Fitting Construction
In this posting here were just going to go through the process of manufacturing 57-10-51 inboard diagonal strut fitting.

This is just kind of an inside look into what takes place during the manufacturing process of some of the components on the aircraft.

The drawings on the builder database are PDF files that are used both by the builders or the assemblers of the aircraft as well as during the part manufacturing process.

The PDF file gives and in context orientation of the part for the overview of where the part is used As well as a detailed three view drawing for manufacturing purposes.

Once again we remind you every time we post something on one of these postings that the drawings are only updated on the builder database and not on these postings.

Best Method For Keeping up with the EMG-6

Most recent EMG-6 information direct to your mailbox. We continue to hear from many of you avid followers of the progress blog. We try to do our best to blog as often as possible. But if you're one of those that are checking the blog 3 to 4 times a day to see what new information is being posted, I think we need to do an intervention. We do appreciate your enthusiastic following but we also have a simpler way to keep track of all new information being posted to the blog.
Sometimes the monthly shop notes can get rather lengthy. 
This process will send you only the most recent of information.

Located on the home page of the blog is a little box titled "follow by email."
Type in your email address and click on the submit button.

27-41-00 Rudder Assembly LD

27-41-00 Rudder Assembly LD

This is an overview of the drawings that are located in chapter 27-41 for the rudder assembly within the builders database.  Keep in mind that the drawings that are located within the progress blog do not get updated as time goes on. Only the drawings that are located within the builders database. Our current and up-to-date and have the most recent revisions.

Fuselage Boom Reference Drawings/Pictures

53-20 Fuselage Boom  We have added some additional reference pictures to help with the assembly of the fuselage boom. These are primarily to assist with the  overall orientation of the components and the assembly process.
These pictures have also been uploaded to the builders database and are available. There under chapter 53-20.

EMG-6 "Shop Notes" November 2015

November "Shop Notes"
"EMG-6 Shop Notes" is a day-to-day accounting of what's going on in the shop with the EMG-6 Electric Motor Glider.

November 25, 2015 Test manufacturing of another (LD) Rudder assembly. Since the temperature has dropped substantially. The productivity and the big hangar which does not have heat becomes impractical.

I asked Jason today to work in hangar seven and go through the process of building the rudder assembly.

We have redesigned the rudder assembly slightly .
All of the components are identical except we have replaced the leading edge with a smaller, lighter weight, and more aesthetic leading edge that incorporates the leading edge spar into the one-piece leading edge. 
This simplifies the construction process And it makes it possible to fit the entire rudder kit into a much smaller package for shipping.
All of the original pieces and holes still line up using the new leading edge piece and those of you that currently have a rudder …

"Trust the Tuck Method" Sport Aviation / Experimenter "Technically Speaking" Article October 2015

"Cotter Pins"  Sport Aviation / Experimenter magazine "Technically Speaking" October 2015 Article Our monthly column in Sport Aviation/Experimenter  Magazine for the month of October was an article on Cotter pins

We discuss The "Tuck Method" of installing a Cotter pin
Trust The Tuck MethodCotter pins have been commonplace in aviation as far back as the Wright brothers. This also appears to have been the same time frame that the last update was made in regards to the subject of cotter pins. Even the * FAA advisory circular (AC) 43.13-1B is unchanged from its original version and dedicates only two paragraphs to the subject: “Cotter pins are used to secure such items as bolts, screws, pins, and shafts. Their use is favored because they can be removed and installed quickly. The diameter of the cotter pins selected for any application should be the largest size that will fit consistent with the diameter of the cotter pin hole and/or the slots in the nut. Cott…

EMG-6 "Shop Notes" October 2015

October "Shop Notes" "EMG-6 Shop Notes" is a day-to-day accounting of what's going on in the shop with the EMG-6 Electric Motor Glider.

October 11, 2015, Light Sport Repairman Maintenance ClassWe are now about halfway through the October light sport repairman maintenance class that we teach each year. These classes happen 3 to 4 times a year in Corning California and are the primary source of income that supplies the capital for developing the EMG-6 aircraft. And as such, for those of you that feel angst during the period of time where we hold the light sport repairman maintenance classes because of the lack of posts on the blog we seek your understanding. 

EMG-6 "Shop Notes" September 2015

September "Shop Notes" "EMG-6 Shop Notes" is a day-to-day accounting of what's going on in the shop with the EMG-6 Electric Motor Glider.

September 29, 2015 Finish Covering of the Left Wing In this picture here we are starting on day two of the wing covering process.
The wing has set overnight and we can now start doing some of the finish tapes.
We should be able to finish up the left wing by this afternoon and get a start on the right wing.
During the construction process. We have been videotaping all of the process to produce a time lapse photography, video of the wing covering.

"Twist Welding" Sport Aviation / Experimenter "Technically Speaking" Article August 2015

"Twist Welding"  Sport Aviation / Experimenter magazine "Technically Speaking" August 2015 Article Our monthly column in Sport Aviation/Experimenter  Magazine for the month of August was an article on Twist Welding cables.

This is technique that we developed over the years and have refined and now use on a regular basis. When working on aircraft with cables of any type.

Watch the Companion Video Twist Weld (Cable End Treatment)
What is Twist Welding? “Twist Welding” is a process for treating the end of a cable to prevent it from unraveling. The idea was originally shared with us by one of our students. He had been in the
cable industry for nearly 30 years and had a more basic version of our technique, but didn’t have a name for it. We coined the term “Twist Welding” while developing and refining the technique.(Figure: 1)

Reno Air Races 2015

Reno Air Races 2015 We took a little time away from the Corning airport this week to attend the national championship air races at Reno, Nevada. I took over 2000 photographs and selected a few here that were worthy of looking at.

EMG-6-250 Fun Flying September 2015 (Video)

Our First flight after returning from the Oshkosh AirVenture 2015 Airshow. After reassembly and a good pre-flight we are back in the air. In this video we decided to get some video from a little different perspective.

Wing Rib Attach Fitting Manufacturing (video)

In this "How it's Made" episode of Building the EMG-6 we see how the Wing Rib Attach Fittings are manufactured.

Wing Rib Manufacturing (video)

In this video we go from start to finish with the manufacturer of the wing ribs. We show several methods by which you can make your own rib  bending fixtures.

Fuselage Boom Kits

53-20 Boom Assembly In this posting of the blog we will have a complete look at the fuselage boom assembly. We will do this simultaneously as we are putting the fuselage boom kits together.
53-20-51 Bulkhead 1

"Make Sure the Pipe Fits"

July Sport Aviation Magazine Article "Make Sure the Pipe Fits" In July 2015, EAA Sport Aviation Magazine started combining Experimenter magazine with Sport Aviation Magazine. Experimenter Magazine for many years had been an online publication. We are really happy to see it back into the main body of Sport Aviation.  As most of you know we are in now writing a monthly article in the Experimenter section. The column is titled "Technically Speaking". The topic for the July issue was pipe fittings and their use in aviation. Each month, after submitting our article to Sport Aviation magazine We reformat the article with additional information and pictures above and beyond what will fit into the space constraints within the Sport Aviation magazine article. We will post this expanded article each month in the blog. We put quite a bit of work into these articles and they generally lend for really good reading.
Pipe Fittings in Aviation.
Pipe threads are used in virtually …

Fuselage Boom Assembly Bulkhead #3 Chapter 53-20-53

53-20-53 Bulkhead #3 Each one of the bulkheads that are manufactured for the fuselage boom assembly are referenced in a 7 page PDF document.
This document can be utilized by the builder of the aircraft as well as the technicians within the shop that are manufacturing the parts.
Page 1 of the PDF shows and overall view of the flat layout and reference dimensions that can be used for many different purposes during the building as well as during the manufacturing of the components from the technician standpoint in the shop.

55-10 Vertical Stabilizer

Vertical Stabilizer Assembly
55-10 Is the Code for the Vertical Stabilizer Assembly.

We have been updating the builder database with new drawings. These are the most current drawings available to the builders. However, it is important that you recognize that only the drawings that are contained within the builder database are updated. Any changes to the drawings occur only on the drawings that show up within the builders database. To have access to all of the builder database you need to become a EMG-6 member and receive a serial number.

To find out more about becoming an EMG-6 builder and member and get started on building your own aircraft. Click here

EMG-6 "Shop Notes" for the Month of August 2015

EMG-6 "Shop Notes" and Index for the month of August 2015In our upgrade the progress blog for the EMG-6 we will be formatting our process slightly different than we have done in the past. Previously we have just rambled on and taken pictures on a daily basis of everything that's happening in the shop. This works out great for following along and just seeing how things work, but in the future we will try and have each post have a little bit more continuity with the previous posts. We will make a page called shop notes an index for each month but we will make changes to each topic page as we progress. This will show a single subject matter from start to finish and help tie all the things that happened over the previous months together with a single subject. Any subject matter worth pictures and explanation we will create into its own post.

Manufacturing 9" Radius Tube Bending Dies

Bending Die DesignAs most of you know that have been following this blog's progress. We have been in a transition period trying to retool as a result of Quicksilver Aeronautics no longer being able to any of our parts. One of the areas that we were outsourcing was the bending of the large diameter tubes that are used for the fuselage keel tube as well as the wing tips on the EMG-6. Several months ago we purchased a  production tube bending machine which didn't come with any tooling. Much to our shock, we found that the tooling costs are outrageous for the dies and mandrels. To purchase a die set for the 9 inch radius needed for the keel and the wingtip. The cost was going to be $2000. In identifying the requirements for bending these 1 inch diameter 6061 T6 aluminum tubes. We realized that on a large radius like this. We could easily manufacturer our own bending die. We designed the die to fit our machine and have begun the process of building the individual segments that we …

Progress Blog Archive Links


Un-Boxing of the Polini 250 Dual Spark Engine

This is the un-boxing video that we shot back in May 2015. Un-boxing videos are fairly popular because of their revealing nature of what to expect when purchasing a new product. If you are going to spend several thousand dollars on a new engine it's kinda nice to see more information about the product before it shows up on your doorstep. So we look at how the engine is packaged and shipped along with what we should expect to see inside of the box with all of the extra components and accessories. It is also a candid look of our first impressions of the motor.

EMG-6 Configurations

The Many Ways to Configure the EMG-6 Aircraft Basic  This is the basic configuration for the primary structure for the aircraft.
The aircraft could be built and flown as an experimental amateur built aircraft in this configuration.
This aircraft in this specific configuration would not qualify as a part 103 legal ultralight. In order to fly this aircraft as an ultralight the airframe would have to be configured with at least one small electric motor or perhaps a small gas powered motor.

In this configuration the builder of the aircraft could assemble a significant portion of the airframe themselves saving a great deal of cost. Our goal is to be of the build this aircraft for under 10 K.

As a single place experimental aircraft the aircraft could be flown with either a glider rating for a private pilot's rating or as a sport pilot rating. As an experimental aircraft no glider rating is needed for single pilot operations.

10 Tips for Using This Blog Successfully

10 Blog Navigating Tips. This blog is currently being populated with information from the old progress blog and once we have completed the propagation of the old information we should have nearly 1000 postings.

As you might imagine finding the information that you're interested in could be a bit challenging.

Hundreds of great articles and resources are at your disposal with just a few clicks.

EAA Hints For Homebulders

EAA video hints for home-builder's section is a great resource for learning about building and maintaining aircraft. We have been participating in the video development for this section of EAA's website since 2008. We have done over 100 videos and webinars. We have provided a link here so that you can take a look at some of the videos that we have done to date.

Click here for link to EAA Hints for Home-builders 

If you book mark this link it will automatically update with any of our new videos that are published.

Rainbow Aviation Services becomes dealer for Polini Motors

Rainbow Aviation Services is currently working with Polini motors to become a major US importer and service center for the complete line of Polini motors. After we complete our initial investigation and testing of the Polini 250 dual spark engine we will make a determination as to the future potential for the Polini 250 being used in the EMG-6. All of our initial testing gives us great optimism that this is the perfect Reciprocating engine Power plant package for the EMG-6. After we have made our initial investigation and decide that this is the motor that we want to invest more time and money this direction we will begin to stock both engines and parts as well as setting up the shop for doing major overhauls and repairs of the Polini series of motors. Combination of Rainbow Aviation and the light sport repairman courses maintenance program should make for the premier service center for the Polini motors. Rainbow Aviation Services will also be visiting the factory in Italy early next …


Polini and the EMG-6 The Polini Motor is one of the Power Plant option that we have adapted for the EMG-6 for those that are wanting longer cross county capability or just in the interim until the electrical power plant systems are more refined. Overview - The cylinder is die-cast in light alloy, it ensures a better thermal stability.

- The piston, gravity cast at high silicon content light alloy, reduces thermal expansion and the coupling slack. The design of the piston top is specific to optimize the compression ratio.

- It is provided with a balancing countershaft; this feature cancels the vibrations and guarantees comfort never felt during a flight and a longer life for the engine itself. The counter-rotating rollers decrease greatly the upsetting torque-steer for an extra comfort in flight.

-The centrifugal clutch is in oil bath with helicoid mechanical reduction.

- The electric starting is standard but to offer the maximum safety the engine is also equipped with manual starter …

EMG-6 Flying at AirVenture 2015 Video

The EMG-6 flew during every available session during air venture 2015. However there was only one session during the very 1st day that we were able to shoot video. My son Kristian was the cameraman. This year at Oshkosh was the best year in 10 years in terms of the attendance in the ultralight area. With I think 30+ vendors also a new record. The flight operations area was very crowded and the amount of flight time was somewhat limited. Most of the flight operations windows were limited And typically we would only get 4 circuits within the traffic pattern before we were shut down. We did manage however to get a total of 4.3 hours on the aircraft at the show.

ATA Chapter Titles (System Identification)

ATA Codes as used on the EMG-6
This page provides the definitions of each chapter relating to a particular section of the aircraft. We are using a modified version of the (JASC) and (ATA) code table. This coding system helped keep track of where information is located for particular components on the aircraft.  This is simply an easy way to organize all of the information related to the aircraft.

All of the Aircraft Part Numbering System is based on this Code.
For Example Part Number 53-20-52  shown at the right
53 Fuselage Assembly     -20 Fuselage Boom Sub Assembly          -52 Fuselage Boom Sub Assembly Bulkhead #2

Country Colors

Renderings of the EMG-6 Our vision for some possible color schemes for the EMG-6

Packing Up For Oshkosh 2015

Loading airplanes into the trailer

Tail Wheel Operation Video

Tail Wheel Operation VideoWe've put together a simple video showing steerable the tail wheel in action. the tail wheel is connected via springs to the rudder. The spring pressure provides for good positive steering without being too stiff. In a couple of segments within the video you can see the tail wheel deflected beyond the direction of travel and the springs allow the tail wheel to simply center up without changing direction. In addition the maximum angle for the tail wheel correlates with the radius with one of the main wheel brakes locked up. This allows the airplane to be turned on a very tight radius pivoting around one of the main wheels.

Main Landing Gear Modifications

Main Landing Gear Modification FinishedWe have finished the modifications to the main landing gear to incorporate the larger 6 inch wheels and tires. We also moved the landing gear aft. We were able to get another hours test flight on the aircraft using this landing gear system. Aircraft handles so much better now. The tail comes up almost instantaneously after applying power. We decided to go ahead and put an extra wide stance on to the landing gear.

Steerable Tail Wheel

Steerable Tail Wheel

We've decided it's time to install the steerable tail wheel option.

We are planning to fly and demonstrate the aircraft at the EAA air venture and the necessity for being able to taxi and maneuver the aircraft on the ground is much different than operating off of our small airport with minimal traffic.

The tail wheel bracket assembly installed on the tail skid. All of the design is intended to be able to retrofit from one type of landing gear to another with minimal effort.

Main Landing Gear Modification

Main Landing Gear Modification