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Introduction
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Tools for Setting up Shop
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Materials for Kit "A"
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Fuselage
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Bulkheads and firewall, engine
mount
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Tail and Rudder-Vators
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Center spar and Stub wing
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Landing Gear
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Outer spars and Wing cores
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Controls, Wheels and Brakes
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Canopy, Forward deck and Turtle
deck
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Seat belt and Roll bar
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Finishing
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Engine and Panel
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FAA Inspection
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Test flight
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Enjoy!!
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Introduction - Safety
Building any airplane is a
daunting task. The Personal
Cruiser has been designed for the
first time builder. Simple hand
tools are all that are required
and a willingness to learn. The
entire aircraft is composite
construction and with the benefits
of a sleek design and 100%
completely compatible structures
comes the requirement for safety.
Protection from possible skin and
eye irritation from working with
epoxy, fiberglass and various
fillers is necessary. Gloves and
a comfortable dust mask are
recommended during portions of
airframe construction. Aeropoxy
has been selected for strength and
for being non-allergenic.
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Tools for Setting up Shop
After placing your kit order, it
would be a good time to set up
your shop with some required
tools. Many of the tools can be
purchased locally; the list below
has been complied for your
convenience from online suppliers.
Tools List <-- click here
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Materials for Kit "A"
There are additional materials
that are not stocked by
Pro-Composites that are available
from three recommended suppliers.
Applied Vehicle Technologies
Wicks Aircraft Supply
Aircraft Spruce and Specialty
Below is a link to a list of
materials that will be purchased
separately. As these suppliers
will carry a fresh inventory to
pick from.
Here is a list to get started:
Kit "A" Materials List
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Fuselage
A flat box will arrive via UPS or
DHL containing flat panels that
will eventually form the fuselage,
seat, turtle deck and forward
deck. It will also include the
hot-wired tail cores and firewall
blank.
The individual panels are
fiberglassed together with
bi-directional (BID) cloth strips
creating one large panel. The
creation of three formers are made
from plywood purchased locally.
Next is the simple process of
“folding” the plane. Basically,
lifting up the large panel (with a
friend) and placing it into
plywood formers. A quick trimming
of a seam line and prep and
fiberglassing of the small exposed
foam core areas lock in the
shape. The seat, turtle deck and
forward deck supplied are
assembled in similar fashion
A
video of the process can by
clicking here:
Cruiser
Kit "A" Assembly Intro Video
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Bulkheads and firewall, engine
mount
The seat is also a structural
component and is mounted
permanently. The firewall is
installed and engine mount hard
points are added. A small bulkhead
is made and installed. The
firewall is wood however it is
later covered with Fiber-frax and
stainless steel sheet metal; which
is standard practice on many
composite airplanes.
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Tail and Rudder-Vators
The construction manual provides
the layout for the twin "Y" spars
for the tail and how to set the
incidence.
The tail cores are attached and
fiberglassed.
Rudder-Vators are then cut fro the
cores and hinge pads are formed.
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Center spar and Stub wing
The supplied center spar is fitted
and a lay-up schedule is provided
ensure the correct strength.
The rear spar is made and ribs are
created from a template. The stub
wing will house the landing gear
hard point and aileron bellcranks.
Eventually split flaps will be
formed just behind the aft spar.
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Landing
Gear
The construction manual includes
detail to fabricate the main gear
legs, however it is recommended
that they be purchased directly
from Pro-Composites. They are a
combined lay-up of S-2 glass and
BID glass. They then are attached
to the main spar shear web.
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Outer spars and Wing cores
The supplied outer spars attach at
the center and end of the center
spar. Supplied Hot-wire foam
cores are bonded to the spars and
then glassed. The Ailerons are
then cut directly from the wing
cores and then reinforced with
carbon fiber cloth.
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Controls, Wheels and Brakes
A center stick provides input for
elevator control to a simply
ingenious mixer design and out to
the ruddervaters. The mixer
completely isolates the rudder and
elevator inputs. Cables
attach the rudder pedals to the
mixer. Ailerons to
differential bellcranks to reduce
adverse yaw.
Simple cable actuated heel levers
are attached to a mechanical
caliper for disc brakes.
Differential braking provides
maneuverability to the castering
nose wheel.
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Canopy, Forward deck and Turtle
deck
The supplied acrylic windscreen is
trimmed and the step by step
instructions will guide you to
create a flip up canopy.
During this process the turtle
deck and forward deck are
permanently bonded to the
airframe.
Gas charged struts provide the
lifting mechanism that support the
canopy.
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Seat belt and Roll bar
The supplied roll bar is added for
safety and also provides a
convenient location to attach the
4 point safety harness.
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Finishing
Sanding and filling will take some
time but goes by faster with a
couple friends for help and
support. After sanding an
automotive filler primer is added
which fills the sanding marks and
then it is taken down with higher
grit sand paper.
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Engine
and Panel
The Corvair was chosen as the
original powerplant because of the
base of people interested in the
engine. As the plane only requires
around 35 hp to fly there are a
number of choices which would work
fine without as much reserve
power. One consideration is an
1834 cc Volkswagen conversion. An
80 hp Rotax or Jabiru motors would
provide and excess of power and be
far lighter than the Corvair.
These engines were anticipated
and the design will accommodate
the various weights.
The panel sports two rows of
instruments with switches on both
sides. The proto-type was planned
for day VFR. The panel is a
personal choice item and can be
made from an aluminum sheet or
fiberglass or carbon fiber.
The entire panel can be removed in
5 minutes as all wiring goes
through a large canon plug.
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FAA
Inspection
A special air worthiness is the
outcome of a passing inspection by
your local DAR. More information
and documentation can be obtained
from
www.eaa.org
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Test flight
Morgan Hunter the primary builder
did the first flight and initial
test flights of the Personal
Cruiser. Stability and successful
flutter testing was accomplished
later.
The PC has a sporty feel to it, a
quick roll rate and very ample
buffet before stall. Lateral
stability is good and no
noticeable wag as found in other
popular V tails. Slips are easier
as there is a slight nose down
tendency with full left or right
rudder inputs.
In all the Cruiser has been an
easy flier and new pilots should
be able to transition from a
primary trainer aircraft without
difficulty.
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Enjoy!!
We estimate that the Personal
Cruiser can be completed in 800
hours or less for a first time
builder.
Our lead "first time" beta builder
has approximately 400 hours into
his project and his airframe is
80% complete.
Building a plane is a rewarding
process. Not only is the building
enjoyable but the hard work you
put into will culminate in an
efficient and affordable aircraft
that is a blast to fly.
If you are ready to take up the
challenge please give us a call.
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Scott VanderVeen
Copyright © 2007 Pro-Composites.
Inc. All rights reserved.
Revised:
12/23/09. |
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