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EMG-6 "Shop Notes" June 2017

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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 2, 2017 We begin the month of June at a frenetic pace. This is our last full month of work that were able to do before we start the countdown for the trip to Oshkosh. The schedule appears to be very tight. Prototype number 3 has to undergo a complete series of flight tests and documentation. We have a large number of parts that still have to be built and sent to customers this month. And our top-secret project of the month is a new electric motor for prototype number 2. More information on that if it materializes will be forthcoming.


We are currently prepping the Polini 252 get ready to run with the new drive system installed. All of this system is now complete and ready for operational tests. We still have a few other things to complete on the aircraft before we can run the engine. The electrical system and starter system has all been hooked up. The co…

EMG-6 "Shop Notes" May 2017

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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.


May 29, 2017 We have added another series of drawings to the builders database.


Bending Sheet Metal (Part 2) Sport Aviation / Experimenter "Technically Speaking" Article May 2017

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Bending Sheet Metal  (Part 2) In part one of this article we discussed, in depth, the theory and the process for developing a flat layout for manufacturing a sheet-metal part. In this article, we will take it to the next step: the practical process of converting the flat layout to a bent sheet-metal part. The tool that we use for bending sheet-metal is called a “brake.” There are several different types of brakes.  A “press brake”, commonly found in manufacturing environments, uses a vertical positioned die bending the sheet-metal over a stationary “V” block.  A “cornice” brake, which has a solid clamping bar the full width of the brake, is limited to simple straight bends. And the “box and pan” brake. The box and pan brake is sometimes referred to as a finger brake because of its individual fingers which can be configured in a nearly unlimited fashion to make some of the most complex sheet-metal parts. If you are interested in purchasing a sheet-metal brake for building experimental…

Getting Started

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How to Get Started Building the EMG-6      Updated May 20, 2017 1  Follow the Project Progress Blog (Shop Notes) The "Shop Notes" blog follows the progress as we design, build, and fly the EMG-6. This progress blog contains most of the up-to-date information about what is happening within the company and the project. 
If you do nothing else make sure that you follow the project. Subscribe to the YouTube channel. Subscribe to the website and blog to get automatic updates of the most recent information.
YouTube Channel Link to and subscribe to the YouTube channel . The YouTube channel contains multiple videos on designing, building, and flying the EMG-6. Subscribe Remember to subscribe to the website and blog. After entering your email address you will receive a confirmation email which you must verify in order to receive email updates.

May 2017 Light Sport Repairman Maintenance Class

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Class Photo Album May 2017  Light Sport Repairman Maintenance (LSRM) Class

Bending Sheet Metal (Part 1) Sport Aviation / Experimenter "Technically Speaking" Article April 2017

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Bending Sheet Metal (Part 1)
We are often surprised by the number of aircraft builders who seem to be intimidated by the process of calculating bend allowance, setback, and simply creating a flat layout for bending a simple part. In this article we are going to back up a bit, and provide some of the theory necessary to understanding how we go about the process of converting a flat piece of sheet metal into a complex sheet metal component. Learning to accurately layout and bend sheet-metal is a very useful exercise. Once you have mastered the process, you will find that it not only saves a great deal of time, but also can save you a great deal of wasted material.
To start with, let’s examine some of the properties of aluminum sheet metal used in aircraft. The two most common alloys of aluminum used in the experimental aircraft world are, 6061 T6, and 2024 T-3. 6061 is one of the least expensive and most versatile of the heat-treatable aluminum alloys. 6061 T6 has a tensile strength of…

Bing 64 (CV) Carburetor Part 3 (Idle Circuit) Sport Aviation / Experimenter "Technically Speaking" Article March 2017

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Bing 64 (CV) Carburetor Part 3  (Idle Circuit)
In Part 2 of this article, we talked about the starting carburetor (choke) system. We can run the engine at lower RPM settings only on the choke system, but as soon as we reset the choke system to the off position, the engine is now running on the idle circuit only. We often use this as a troubleshooting exercise. If the engine runs with the choke partially on, but dies as the choke is placed in the off position, it is an indication that the idle circuit is the culprit. It is absolutely essential that the idle circuit be set up and functioning properly. We use the idle circuit on every flight, and it is a surprisingly important system within the carburetor. Aside from the practical aspects of having a properly operating idle circuit, there are many correlations with the idle circuit malfunctioning and other engine problems, ranging from increased maintenance to engine stoppage and even engine failure.
If you follow our articles on a regu…

Bing 64 (CV) Carburetor Part 2 (Starting Carb) Sport Aviation / Experimenter "Technically Speaking" Article February 2017

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Bing 64 (CV) Carburetor Part 2  (Starting Carb)

In Part 1, we examined the basic principals of operation of  the CV (Constant Velocity) carburetor. In this article we will take an in depth look into one of the most misunderstood subsystems of the carburetor, the “Starting Carb”.  It is often referred to as the “choke”, however, this  doesn’t properly describe the operation of the Starting Carb.  A choke is, really, a valve on the inlet side of a carburetor used to restrict the flow of air through the carburetor. This results in a low pressure with the intake manifold and carburetor system as a whole. This is different from the carburetor butterfly valve which is located down stream from the fuel nozzle which also restricts the airflow creating a low pressure, but only within the intake manifold. The choke valve which is located before the fuel nozzle presents a low pressure to the entire carb. This low pressure, naturally draws more fuel through the carb and into the intake manifold …

EMG-6 "Shop Notes" March 2017

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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.

March 24, 2017


The elevator control horn being machined from .125 4130 steel plate.

Syncmaster Rans Installation

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This post will focus on the installation and testing of the Syncmaster throttle system that we have installed on our Rans S6 Coyote.

March 01 2017  We begin the process of installing the Syncmaster throttle system with selecting a location to mount the Syncmaster.


For the installation of the Syncmaster on the Rans we decided to install it on the firewall. We chose to mount it in the radiator box as you can see in this photo.

EMG-6 "Shop Notes" February 2017

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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.
 February 20, 2017 After we finish welding the Polini 250 motor mounts we have to protect the tubes from corrosion.


Here you can see where we have removed the self etching primer before welding. This leaves the frame susceptible to corrosion.


We have also drilled pressure relief holes. These help prevent pressure buildup inside the tubes as we weld them. If the pressure is allowed to build up it can cause the weld to blow out.

Sync Master (Bill Stone)

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Bill has volunteered to be our first out of house tester for the Sync Master throttle system for the Rotax 912 engine. This blog will be updated with information every time that he comes in to the shop. We installed the Sync Master throttle system on his Just Air Super Stol which has a Rotax 912ULS 100hp engine installed.
14FEB2017


You can see the slack in the cable at the carburetor after 49 hrs of operation. Originally there was only a small amount of slack. It is possible this was simply caused by the new cables stretching a little. He still had a full stroke from idle to full throttle so this slack was of no significance to the Sync Master's operation.  



2017 National Aviation Technician of the Year (Press Release)

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General Aviation Awards Committee Press Release
Brian John Carpenter of Corning, California has been named the 2017 National Aviation Technician of the Year. Very simply, Brian has become the go-to guy when it comes to the construction and maintenance of—and education about—Light Sport Aircraft. Anytime he’s not teaching a Light Sport Repairman Workshop, you’ll probably find Brian in his hangar at the Corning Municipal Airport working on his Electric Motor Glider or creating an aviation educational YouTube video. Brian has had a passion for aviation since he was a child, building and flying RC aircraft. In junior high, he progressed to building a self-launching glider out of homemade materials and started jumping off a small hill trying to fly. In 1979 he earned his pilot’s certificate while in the Navy. After graduating from Helena Vocational Training Institute (Montana) with his A&P mechanic certification, Brian worked as a lead mechanic for Aero Union, a large aircraft operatio…

Bing 64 (CV) Carburetor Part 1 Sport Aviation / Experimenter "Technically Speaking" Article January 2017

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Bing 64 (CV) Carburetor Part 1 This article will focus on the Bing 64 CV (Constant Velocity) carburetor. The basic principal of operation utilizes a vacuum operated slide  that varies the venturi size which, in turn, maintains a constant velocity of air passing through the carburetor at all engine power settings. The  advantage of  the CV carburetor is  that  it  supplies  the  engine  only  as much  fuel/air  mixture  as  the  engine  demands. For an aircraft applications, where we have large excursions in altitude, this is exactly what the doctor ordered. The Bing 64 carburetor (Figure: 1) has become, hands-down, the most popular carburetor used in the light sport industry. It is used on both the Rotax 912 as well as the 914. It is also used on the HKS 700 E, the Stratus, the Rotec Radial, and the Jabiru engines. This carburetor has a long history of great reliability, on a plethora of aircraft. 

EMG-6 "Shop Notes" January 2017

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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.



January 30, 2017 For the last 16 days straight we have been engaged in a light sport repairman maintenance class.  This is one of the smallest classes that we've ever had. Four of the students that signed up for this class had to pull out for various reasons just before the start of class. The wintertime classes are always limited to  a maximum of 12 to accommodate the facilities during the cold winter months. As it turned out the best day, weather wise, of the entire class was the last day. All of the students graduated with flying colors and will now move on to utilize their FAA light sport repairman maintenance certificate in different ways. Although this was a small size class of only 8 students, they came from pretty much every corner of the United States. And unlike a normal class, we had no foreign students this time. The next class wil…

Brushless DC Motor (How it Works) Videos

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Brushless DC Motor (How it Works) Videos





Low Cost Hydroforming (Video)

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Low cost hydroforming on the Rainbow Aviation Video channel with your host Brian Carpenter. In this episode were going to be taking a look at a low cost way  to manufacture your own aluminum hydro-formed  parts. This is a companion video for technically speaking article published in the May 2016 sport aviation magazine

Dan Kokenge Design

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An email came across my desk today. Thought I'd share it. Innovative ideas going all over the place these days.
January 26, 2017

Wow! I saw your video. I thought I was the only one working on this.  I agree that electric is the way to go. The military has pretty much said that all new craft will be electric.

Builder Ed. Santucci S/N 16-027 North Carolina

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Builders  Ed. Santucci S/N 16-027 North Carolina
January 13, 2017 Ed's latest Pictures




Lift Strut Attach Fitting (Video)

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53-10-50 Lift Strut Attach Fitting Video In this video we go through the installation process of the lift strut attach fittings on the fuselage frame.

Seat Support Tubes (Video)

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Seat Brace Tube Installation P/N 53-10-02-106  and P/N 53-10-02-107 Tube installation onto the fuselage frame.



Ultraflight Batteries Donald Lineback

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"Donald Lineback" Batteries
  Donald Lineback and his latest E-Mail.

 January 7, 2017   News about what to buy:   Before looking at batteries - consider the voltage current demand. Let’s compare voltage to gasoline. One gallon of gas contains 33.7kWh energy according to EPA or 33,700Wh. How big of battery would that be? An NCM Lithium-Ion pack would be 33.7kWh, 172 cells, 635v, 107Ah and weigh 927 pounds. If you factor in the fact that the average car only gets 23% of that energy - the battery pack would still weigh: 213 pounds. So adding a big current demand is not good. Nor is it a good idea to equate the battery pack weight to 5 gallons of fuel in ultralights. ("apples to apples”)

For Sea-Kite.com the number one incentive was to build a highly efficient motor and use less energy. It has been easy for some motor designers to make high kW demanding motors. The problem - airplanes just couldn’t carry enough batteries. Big motors also disqualify themselves to …

Top 10 apps for the aircraft builder. Sport Aviation / Experimenter "Technically Speaking" Article December 2016

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Top 10 apps for the aircraft builder
“There’s an app for that.” This overused cliché becomes more and more apropos every day. Even for the aircraft builder, we now have a virtual toolbox in our pocket that has become indispensable. We have reached the point in technology where it is now the norm for an aircraft manufacturer to publish maintenance manuals, parts manuals, and all other documentation, for that matter, in a digital format. If you’ve grown up on paper, the transition to digital can sometimes be difficult, but the rewards are well worth the effort.


#1 The PDF Reader App:(Figure: 1) The Rotax manuals, for example, consists of literally thousands of pages spanning more than a dozen different manuals. The ability to use a search function on a 500-page manual can really speed up the process of locating the information that you’re looking for. In our shop, we have a library of aircraft maintenance manuals accumulated over the last 40 years.