Showing posts from February, 2016

EMG-6 "Shop Notes" February 2016

"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.

February 29, 2016"Spark Plugs and The Rotax Engine: Part 1" Sport Aviation / Experimenter "Technically Speaking" Article February 2016 February 26, 2016 More files added to the builders database for the main landing gear assembly.

"Spark Plugs and The Rotax Engine: Part 1" Sport Aviation / Experimenter "Technically Speaking" Article February 2016

Spark Plugs and The Rotax Engine:  Part 1

We continue to see problems surrounding the use of spark plugs in Rotax engines. Many of the rules which we have used in the past for typical aviation type spark plugs, used on air cooled engines, no longer apply to the automotive type spark plugs used in a Rotax engine. As with most technical subjects, an underlying understanding of the theory and physics involved is essential to our ability to make good judgments about the use and operation of spark plugs. So let’s start with the basics.

The spark plugs used in the Rotax engines are specific to each type of engine. Figure: 1. The most prolific of the Rotax engines is the 912S 100 hp and it uses the DCPR8E. Figure: 2. Using this plug let’s look at the part number designation and what each one of the numbers and letters indicate for the design of the spark plug.

Spark Plug Size: The (DC) in the part number is the thread diameter and pitch. Looking at the NGK part numbering chart, it indicates t…

Carol's Transition Training in the EMG-6-250

In this totally unscripted video we see the start to finish process of Carol making the transition to her first flight in the EMG-6.

Carol Carpenter Fly's the EMG-6

By Carol Carpenter

The thing about life with Brian is that everything happens "suddenly." There was no discussion leading up to Brian setting up the EMG for me to fly this evening . . .so I did not have time anticipated the event. He just asked me to sit in the plane and started adjusting the seat. The next thing I know, I am in the pilot seat and, to be honest, somewhat apprehensive.
I am buckled in, with a helmet on, and thinking. . . I don't know about this.

25-30-33 Pilots Seat Back

Builders Guide 25-30 Ergonomics 25-30-33 Pilots Seat Back

These pictures that we are covering here show some of the old design pilot seat latching mechanism. We will modify that design

25-30 Ergonomics

Builders Guide25 Equipment and Furnishings 25-30 Ergonomics

Link To Builders Data Base 25-30 Seating Assembly 25-30-01 Pilots Seat Assembly25-30-33 Pilots Seat Back Standard 25-30-34 Pilots Seat Back Hinge 25-30-50 Pilots Seat Belt 25-30-51 Passenger Seat Belts

55-22 Horizontal Stabilizer Trim (video)

"Designing the EMG-6" (Video) In this video we look at the design of the electric stabilizer trim system for the EMG-6 electric motor glider.

EMG-6 Airshow 2015 Set Up (Time Lapse)


Re: Is the EMG-6 capable of meeting the Part 103 using the Ploini Thor 250 engine?

On Thu, Feb 11, 2016 at 12:31 PM, steve wrote:
You have received a contact request from a visitor to your storefront at

E-mail Address: ***********
Name: Stephen **********
Company: ************
Phone Number: *************

Is the EMG-6 capable of meeting the Part 103 Ultralite requirements using the Ploini Thor 250 engine?

Does the pricing of the kits, IE Rudder Kit, Fuselage kit, include shipping?  What would be shipping to 65810?

Does the cost of the Platinum series include all parts and shipping?

What parts must the builder supply and the average build time?  I know, you have been working on this design for several years, and are still building!  Good for you!  But what about the average person?

What would a complete kit cost, picked up in Corning , CA. without a motor.  I need a vacation!!


Thank you,
The Quick Shopping Cart Team

72-40 SINETON A37K154 Electric Motor

Builders Guide72 Motors 72-40 SINETON A37K154 Electric Motor

Potential Motor for the EMG-6 A lightweight coaxial air flow cooled permanent magnet synchronous motor designed to directly drive a propeller. Optimized for high continuous torque density and efficiency. With 17 kg of weight (option dependent) it's capable of supplying up to 30 kW of continuous power at 2000 min-1 providing higher than 93% efficiency. The speed-torque diagram of the A37K154 with a three phase 14Y2 winding configuration is displayed on the bottom figure. The curves are stipulated for different DC bus voltages, without any field weakening applied.
Link to Builders Data Base and  full PDF

27-41 Rudder Assembly (LD)


Front Windshield Prototyping

During the prototyping process, It's really easy to become reliant upon Solid Works and 3-D modeling capability. In this case these wings are slightly modified from the production wings and as such this will be a one off set of fairings. When you're building a one off  project the amount of work necessary to complete all of the 3-D modeling becomes impractical. but like with all of this design work the ability to be able to visualize in your head before you begin the process becomes invaluable. In this post will take a look at start to finish of our design prototyping and see where it takes us.

Before we can begin the process of fitting the front windshield to the aircraft, we need to build the prototype center section fairing that will gap the two wing halves to the fuselage boom. The center section has to be built up to be able to fit the  BRS parachute and between the framework of the upper wing box.

Re: Please explain the levels of purchase and what is gained by the various steps of purchasing

On Tue, Feb 9, 2016 at 7:00 PM, steve; wrote: You have received a contact request from a visitor to your storefront at

Name: Stephen ********
Phone Number:

Having rebuilt and built an ultralite, I currently own a brand new Polini Thor 250 which I was going to replace my current engine.  The EMG-6 intriques me as an aircraft that might better utilize this engine.

Please explain the levels of purchase and what is gained by the various steps of purchasing.  I do not have the welding skills, so the cabin welding is a problem.  The sheet metal and fabric work I have skills.

Would a visit to your Corning, CA location be educational on my part?

I have gone to ultralite training with Bill Bardin at Lodi and am intrigued with California flying.


Steve *******
Springfield, MO

Thank you,
The Quick Shopping Cart Team

EMG-6 Goes Open Source

Breaking NewsWe have decided to change our basic premise on marketing and selling the EMG-6. Our confidence level in the basic design of the aircraft is so high that we feel we no longer wish to hold it back from the general public. Working in the model of Google we feel that in the long run we will be able to monetize a project to recoup some of our investment. From the very beginning we have elected to  not take on investors and simply develop the aircraft at a pace that we could fund in-house. Many of the new builders may not purchase very many parts at all, but many of them will be purchasing parts on a regular basis. We believe we can make a living off of the small margins. In addition, many customers will probably want fast build kits which we will be able to supply.

57-70 Windows

Builders Guide 57-70 Windows

73 Batteries

Builders Guide 73 Batteries

Until this page is up-to-date simply search for the keyword batteries in the search box and you will find several references to battery information.

Post Links
Rainbow Aviation's letter to the FAA office of legal counsel regarding the use of batteries in part 103 aircraftPlettenburg Predator 37 motor installation Lineback Batteries

25-20 Tow System


25 Equipment and Furnishings

Builders Guide 25 Equipment and Furnishings 

25-10 BRS (Ballistic Recovery System) 25-20 Tow System25-30 Ergonomics

EMG-6 Builders Guide

The ATA Code Index This system links to each of the sub-assemblies to their own pages.

01 General02 Tools 11 Placards25 Equipment and Furnishings27 Flight Controls 31 Instruments32 Landing Gear 51 Structures53 Fuselage55 Stabilizers57 Wings61 Propellers 71 Power-Plant General 72 Motor73 Batteries 76 Engine Controls
To access the builders database  click on this link

53-10 Fuselage Frame


53 Fuselage

Builders Guide 53 Fuselage

Builders Data Base Link To Fuselage
53-10 Fuselage 4130 Steel Frame 53-20 Fuselage Boom Assembly 53-30 Fuselage Components 53-31 Nose Skid53-40 Keel Assembly53-50 Wing To Fuselage Fairings 53-51 Forward Fuselage Fairings 53-60 Fuselage Aft (Fairings)

53-10-00.00 Wing Box Assembly

53-10-00.00 Wing Box Assembly OverviewBuilders Data Base Link to Wing Box Assembly
Builders Data Base Link to Welding Fixtures

Jig Components required to manufacture 53-10-00.00 Wing Box Welding Fixture.

53-10-00.01 Wing Box Base(1)
53-10-00.02 Wing Box Side (2)
53-10-00.03 Wing Box Center Spacer (1)
53-10-00.05 Wing Box Alignment Block (4)
53-10-00.06 Wing Box Lower Leg Spacer (4)
53-10-00.08 Wing Box Upright Spacer (4)
53-10-00.09 Wing Box Spar Alignment Block (2)
53-10-00.12 Wing Box Lower Cross Tube Spacer (6)
53-10-00.15 Wing Box Boom Attach Spacer (2)

53-20 Boom Assembly


32-15 Tail Wheel Configuration (TD)

32-15 Tail Wheel Configuration (TD) OverviewBuilders Data Base Link to 32-15 Tail Wheel (TD) MLG

32 Landing Gear

32 Landing Gear OverviewBuilders Data Base Link To 32 Landing Gear
32-10 Mono Wheel Configuratiom32-15 (TD)  Tail Wheel Configuration 32-35 (NG) Tricycle Gear Configuration

"Carburetor Synchronization" Sport Aviation / Experimenter "Technically Speaking" Article January 2016

Sport Aviation / Experimenter magazine "Technically Speaking" January 2016 ArticleOur monthly column in Sport Aviation/Experimenter  Magazine for the month of January was an article on Carburetor Synchronization.

Carburetor Synchronization With the proliferation of the Rotax 912 80 hp and the Rotax 912S 100 hp engines, the topic of carburetor synchronization has come to the forefront. Until about the 1980s, the popularity of Continental and Lycoming engines dominated the general aviation market, these engines used a single carburetor providing for a single source of air and fuel to the cylinders. The use of dual carburetors was primarily relegated to the area of the two-stroke ultralight market. And, even with these engines, the process of carburetor synchronization was quite simple and reliable. However, with the popularity of the Rotax 9 series engines, it has become important to understand a little bit more about how the induction system works on this amazing little powe…

57-10-09 Wing Fold Fitting


53-40 Keel


57-10 Wing Assembly

Builders Guide57 Wings 57-10 Wing Assembly

57-10-06 Rear Spar Attach Plate 57-10-08 Wing Fold Strap 57-10-09 Wing Fold Fitting 57-10-10 Main Wing Spar Inboard 57-10-11 Trailing Edge Spar 57-10-22 Tube Connector 87° 57-10-23 Tube Connector 90° 57-10-25 Fuselage to Rear Spar Adapter 57-10-26 Fuselage the Wing Adapter 57-10-40 Outboard Compression Strut 57-10-41 Outboard Drag Strut 57-10-42 Inboard Compression Strut 57-10-43 Inboard Drag Strut 57-10-44 Tip Compression Strut 57-10-45 Tip Drag Strut 57-10-50 Diagonal Attach Plate 57-10-51 Inboard Draggable Strut Fitting 57-10-52 Leading Edge Tip Socket 57-10-53 Trailing Edge Tips Socket 57-10-54 Wing Tip Bow

57 Wings

Builders Guide 57 Wing

57-10 Wing Assembly 57-40 Wing Struts 57-45 Jury Struts 57-50 Wing Fabric 57-60 Wing Fairings 57-70 Wing Ribs 57-70 Wing Tips 57-80 Wing Gap Seals

57-10-25 Fuselage to Rear Spar Addapter


57-10-08 Wing Fold Strap

Builders Guide57 Wings57-10 Wing Assembly 57-10-08 Wing Fold Strap

Link To Builders Data Base for 57-10-08 Wing Fold Strap

PDF  57-10-08 Wing Fold Strap
PDF 57-10-09 Wing Fold Fitting Installation

57-10-09 Picture Data Base

 The 57-10-08 Wing Fold Strap is shown in context in red.

The wing fold strap is designed to be used in conjunction with 57-10-09 wing fold fitting. And can be used with or without the wing fold system incorporated into the wing design.

There is a total of 4 fittings for the entire aircraft. 2 for each forward main spar.

Although these pictures are shown slightly out of context is are being installed after the wing fabric covering is already installed the process is basically the same. If the wing spar's are already pre-drilled the installation is relatively straight forward. Simply insert the wing fold strap to the inside of the spar and pull (3) 3/16 inch aluminum pop rivets to hold in place. If this is a retrofit than place one of the wing straps on the outsid…

02 Tools

Builders Guide
02 Tools

Recommended tool list for  building the EMG-6 electric motor glider

This is a work in progress, and we will add to this as we continue to go through the construction drawings and videos.


Hand Tools Most everyone considering the project of building the EMG-6 electric motor glider will already have handtools. The list the handtools individually would be a futile exercise as there are many ways to skin a cat when it comes to putting a nut and bolt together on an airplane. Normally speaking a small $100-$200 craftsman tool set with inch and metric sized tools and primarily 1/4 inch drive sockets will do most of the work that you need on the aircraft.

Specialty Tools

01 General


57-10-06 Rear Spar Attach Plate

Builders Guide 57 Wings57-10 Wing Assembly 57-10-06 Rear Spar Attach Plate

The rear spar attach plate has both a left hand and a right-hand component.

Shown to the right is the part for the left side of the aircraft

These parts can be used as a replacement for the  "U" Bracket used on the UL version of the Aircraft.

Link to builders database for the Rear Spar Attach Plate 57-10-06Picture Data Base 

61 Propellers


72-10 Plettenburg Predator 37 Motor

Builders Guide72 Motors 72-10 Plettenburg Predator 37 Motor
Although we have completed our flight test phase using the predator 37 motor, we will continue to publish data to this section about our findings on the motor.

Initial Summary: The predator 37 worked very well with the prototype aircraft for meeting the part 103 requirements to make the aircraft a legal ultralight. The aircraft was able to maintain altitude and even climb (100 FPM) the ability to pull power settings necessary to maintain altitude was primarily limited by the amount of heat that the motor generated during these high-power setting operations. Although we did not burn up a motor. After the flight test series was conducted we did notice discoloring of the windings and obvious indications that the motor was operating beyond the normal operating temperatures. We were able to prove that the aircraft performance was adequate operating even with this small of motor and propeller combination which gave us some very goo…