EMG-6 "Shop Notes" June 2017

"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 coolant system is now filled and ready to run. Once the aircraft receives its new wheels and brakes we will be able to take it out on the flight line and begin testing.

We have recently contracted with Black Max brakes to be the primary supplier of brake systems for the EMG-6. Although we will have additional options for other types of wheels and brakes on the aircraft we will be focusing prototype number 3 on developing the drawings and installation procedures for the Black Max Brakes.

In order to use the Black Max single lever master cylinder we had to modify the control stick to allow the transition of the plastic hydraulic line to transition through the center of the control stick in order to prevent binding and pinching and possibly damaging the hydraulic line. This also required a modification to the control stick to change the angles so that the brake master cylinder would not hit the instrument panel.

The exit hole for the hydraulic line keeps the installation very clean with minimal bends in the line and an easy transition to the aft portion of the aircraft where the hydraulic line will be teed out to both brakes.

We are currently working on a production run of 10 steerable tail wheel assemblies. In the picture above you can see the main body of the tail wheel housing being machined from solid aluminum billet. 6061 T6. There is a total of 16 different machining operations that take place just for this 1 single part. It has to be reindexed 4 times, so the machining jaws have to be machined to allow reindexing each time that we rotate the part to a new orientation.

Once all of the G code is established the actual process of machining the parts is fairly automated.

The new installation of the Polini 250 inside the fuselage is looking really good. By the time we get the covers onto the fuselage this should be a very low drag profile.

Jason has continued to perfect the wiring system making one bundle that is tucked neatly together and has welded tabs along the fuselage to clamp the wire bundle to.

Worst-case scenario with the control stick all the way forward shows that we still have plenty of clearance from the hydraulic brake lines to the instrument panel.

On the Polini 250 installation we can weld in some additional structure to enhance the seating arrangement. Because of the permanent installation of the motor in the rear seat the ability to be able to utilize that space is no longer an issue. So we have added in an additional tube that will allow us to form a bucket seat. We will probably add a vertical section that will provide a headrest as well.

The demand for parts continues to come in and so we are constantly ordering raw stock material. In the last 2 weeks we've ordered over $10,000 worth of raw material to have on hand for manufacturing other components of the aircraft. This box contains 12 foot sections of aluminum tubing to be used in primarily the wings and flight control systems.

This section of aluminum tubing is for manufacturing push pull tubes for the aircraft. All of the push pull tubes except for the long tube that is used for the elevator control system that is inside of the fuselage boom assembly are manufactured from 6061 T6 aluminum .625 ×.035. This will allow us to finish up the control system on the aircraft.

The MS 20219 – 2 pulleys are used in the rudder control system. These pulleys are quite expensive so we have manufactured some lower cost aluminum pulleys that can be CNC machined without bearings in them that we will be testing.

We are constantly ordering new stock of hardware for both shipping to customers as well as using in the shop on a regular basis for building the prototypes. There's nothing worse than being in the middle of a project and running short on 1 or 2 simple parts.

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