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Showing posts from June, 2016

EMG-6 "Shop Notes" June 2016

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"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.
June 29, 2016 Aft Fuselage Enclosure we have finished the lower wing gap seals and are now proceeding to enclose the aft cabin area. The aft fairing will be covered with poly fiber covering just like the rest of the aircraft. The area from the aft fairing and aft fuselage bulkhead to the forward fuselage Bulkhead will be covered with a removable background sailcloth covering. We will be installing a window into this panel.



The 3D Printing Revolution Sport Aviation / Experimenter "Technically Speaking" Article June 2016

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The 3D Printing Revolution
We are on the cusp of a new era in experimental aviation like we have never seen before. We often hear doom and gloom from those who have been in the general aviation market and who have seen the downturn in the number of active pilots and airplanes coming off the factory floor. The overused cliché “it’s always darkest just before the dawn” is really apropos in this circumstance. We are here to tell you that the future of aviation looks very bright. There are several paradigm shifting technologies that are changing the world of aviation equivalent to that the Wright brothers first flight, the dawn of the jet age, and Burt Rutan’s contributions to composite aircraft. Some of the most exciting of these new technologies which we have embraced, include, electric propulsion, 3-D solid modeling software, and 3-D printing. Over the next couple of months, we will be writing articles exploring, in-depth, some of these new technologies which are rapidly becoming tang…

3D Printing The EMG-6 (Video)

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A look at the use of 3-D printing technology to build the EMG-6 Electric Motor Glider. All of the 140+ 3-D printed part files available for free download.



Tube Marking Tools

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Tube Marking Tools For the builders that are building the EMG-6 from plans and the basic kits, There are a lot of holes that need to be drilled in the tubing throughout the build process. As a result we have developed a series of tube marking tools to assist us in the shop for ensuring accuracy during the marking and drilling process. And although we have many of the parts being manufactured with CNC machinery, there are still a significant number of tubes that need to be marked and drilled during the manufacturing and especially assembly process.

We have found these tools to be so useful in the shop that we have decided to make them available to the builders of the EMG-6. This series of tube marking tools that can significantly improve the ease and accuracy of marking round tubing.

These tube marking tools have a multitude of features which can only be created practically through the use of  3-D printing technology.

The tube marking tools are manufactured from 3-D printed ABS pl…

"Video" EMG-6-250 Local Flights

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Carol Carpenter Flies the EMG-6-250. These are the last flights on the EMG-6-250 . The engine and many of the parts were removed to complete Prototype #2 in order to start the Installation of the Polini 250 into the Cabin of Prototype #3. This will be a completely enclosed version similar to Prototype #2 but #2 is currently being fitted with the Electric Power Plant.

"Video" Cutting Flight Control Gap Seals from Pool Noodles

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Cutting Flight Control Gap Seals from Pool Noodles





In this video we go through the process of converting pool noodles into low-cost lightweight, and easy to install  foam gap seals for the EMG-6 electric motor glider.
Let's go through the detailed procedures on how we came up with the final results that we have been using on the EMG-6 electric motor glider. We have cut nearly 30 different dies and guide blocks to come up with the final results that we found that work very well.

R&D Motor

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R&D Motor  This page is dedicated to  any updates and information regarding the R&D Motor.


 June 9, 2016   Motor Update Today we had a meeting with Ed Donovan owner of R&D cable. Ed and his team are developing an electric motor that will be used on the EMG-6 electric motor glider. The design parameters are basically to design a 20 hp continuous operating motor turning at 2500 RPM and producing approximately 65 foot-pounds of torque. We will be spinning a 48 inch diameter propeller. this motor is simply a dummy motor that does not have the winding's and magnets inside but was delivered so that we can use it for the development of the motor mounting system on the EMG 6 as both as a pusher and as a tractor on the to the wing pylon locations. The bolt pattern is the standard two-stroke Rotax engine bolt pattern. the bearing is the same as the front bearing on the Rotax E gearbox. The total motor weight will be in the neighborhood of 25 pounds when completed. T…

Low-Budget Hydro-forming Sport Aviation / Experimenter "Technically Speaking" Article May 2016

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Low-Budget Hydro-forming
We are often looking for methods for creating parts on our experimental aircraft that replicate the professionalism of factory built aircraft. The biggest stumbling block is usually the cost of set up for fancy tooling and machinery. Yet, you might be surprised by what you can accomplish in your own small workshop. In fact, many of the greatest ideas in aviation originated from small workshops like yours.