Showing posts from August, 2015

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 …