CONTROL LINE SPEED IF YOU READ MY 1994 NATS REPORT about Speed competition Lubbock last July aware extraordinary performance FABS Team Bob Fogg Carlos Aloise George Brown III Howard Sheehan outstanding speeds result much dedicated work expertise member contributes share Carlos engine builder learned about engine treatment years ago teenager top competitor Navy Carrier event worked engines fathers machine shop learned sleeve piston fit important part engine work get maximum performance father pit man won contests SuperTigre 35-powered airplane won Nats year Carrier Event Director disassemble engine due protest another competitor time rules specified no modifications engines no grinding timing changes new-parts substitution Carlos just worked piston sleeve get proper fit allowable other competitor sure some secret filing grinding engine since outperformed drastically Other modelers like Bob Burch Combat George Aldrich Racing also knew fit particular engine improve its output Carlos took 19-year vacation modeling included five years Navy marriage kids things like started flying again decided build own engines designed ACE Aloise Competition Engine think built two 21s first 049s 65s thought would try give idea just much work build high-performance engine like ACE Nelson Jett Wiley First have have enough sense know design engine make drawings parts must know about design sleeve port timing valve timing materials would likely start crankcase several ways obtain blank casting hardest way make hog out bar stock like Charlie Legg does its much easier make patterns have sand-cast investment-cast going make production run might make cast-iron permanent mold small number good castingsyou would likely use investment lost wax method gives good solid nearly finished castings Carlos uses method Start making exact pattern what want oversize allow shrinkage molten aluminum metal wood plastic combination Put reinforcements bypasses fins intake exhaust ports Make two patternsone outside case inside shape Use cast female epoxy mold force molten wax outer mold easyits made halves split apart wax pattern comes outbut inside difficult inside core pattern has cylinder bore exhaust hole crankshaft bore intake opening bypasses bearing bores piece cant get out wax pattern either have make totally demountable parts unbolt another make wax crankcase pattern two halves lot easier have accurately join left- right-hand pieces together additional melted March 1995 129 Authors Class B model uses engine built using ST 29 parts crankcase Bill Wisniewski some hand-crafted parts Bill Nusz Slugger Brown take break 1994 Lubbock Nats Al Baker Sam Burke Bud Hughes background FABS team working ACE 65 engine after rotary valve blew apart during backup flight record-setting run ABBREVIATED 8414K 1/24SZ 1/lASS 1/B SI 1/6 SZ 114021 37Dollar1000Bat22920321o93266944132998 40VOOghI Core F40209203092660045 15Coo JN4D Jenny215183292465938 86 952. 27LIodheog 802111591434 92469934 91948 29Wato TapooW1ng159142292045346048p062 36Westlod Lysander259183792475300 2 35 DOll 046A 0440 23924 34932 6894629 Boe ng 100 Spool 15916 224924 45 361609909 9 33StIn TrIeotoo30930459389062120 7 39Intl LI p382719392678 45 39Coo P3 F ghto18415282056 34 I2956 25Vgt Coo 0201/4182022854 44089 38COn Catina P05552487860 19CorEl. 814624669489 17FOkI0o 07 Fto14122116 930o4949 31Boyle GeeBoo1149121741435932 494470956 13Seprrlee S6E15$i022491364492660 3889 52 36Doe Gelfhawk14481421491843936SCALE P1414 35Lotk EletOro #1127925419325593BLook Elet 94 43Gem Arteger TBF3092840838.808 2Ford 314 4AT6 42Bee 1170 FlyFort5194077 95k00 1170 96 38MA l4itcIeell 82536483755 952A 025 96 34lAeoolCaetolOBZ72154815239224649351 14 826 6 37Coo Navy 003111981828492457936StIn Tn 4 25CBaoeo 1311 42118151649203BodlyPo o 6 34Doeg Toanep DC34794071 850oc Coot Hawk P6E15491523492267 4 4 32DoolIttlee GIfli12491718492237 3549 46 74958 31Roe 741364 P12815916224920444922594 64 89558 32Spofld RollDog1349162092040932S 8 32Homod Ike6lllike1048121549153192662945 34Tooner OW Rater13 $1219491639 285 90 7B952 35How ken ItellIgan1601523402047 3264 44 94 56 33Roe P26A Low Wog14$1521 20 423263 4584 58 35Stlneen TW SE720491631492562 4582 55 23 66 4208 8leeqeite Boeb37492441935 8150408965 37Stearean 711716 91824482249 3 30TABIG 8ke Tea13144 1321 1843 36860$ 438 Ilk WIdow 86133 O495099 75 42CHeIldIvr 0121425 82537 935 26Food Toleato 443883857 4814 72* 31RelIant Alo Roe3292248 3096 52 330ro J2F Dook19 2829 4058 558 68 27CSeehawk 771115 lB23 24 2801k Ah1b 03836 3454210 4 2 16IlPg 0400 Soak50 4575 56 31LIOdFe LSloIoe21916314 228 936 31Hoomod RtPete1O9121591530930 31C Spoohwk 79121248131992238 3550 8 7695B 33Aeroota 13 Spt1891027914534926107948 38looeero Poeto Ip12 81618 920379364994917449 03WeIght FlIer20 1830 24604038 READ BEFORE OBDERING*328 SCALE 1132 SIZE 1419818MM ORDER915 ooPLANS AVAILABLE AT ONE BE SURE TO AD T8E 800- DOLLAR UNDERUD4 SIZE AL 10Z FOR FACKAGING PRICES FOR ALL DESIGNS FOOTAGE 4210 IBSOSA5lCE T T8000ANO A001TIO8AL FLANS MANY SIZES e SOc975 CATALOG 9200 OR FRICE LIST ALONE 91SY___________________________________ AIR FOREIGN 93 LAND HI10 Bowman HIC Arcra Giant Scale Plans 28% Ultimate Biplane 3200 us 30% Ultimate Biplane 3500 US 33% Smith Mini Biplane 3500 us 33% Extra 230 available soon.. 3500 US prices include shipping handling "We FIq WhatBowman R/C Aircraft ilesiQn"41212 #3Rd YaFFow BC Fiberglass CowlsCanada VOX 2A0 Wheel Pants Gear Etc AvailablePh 504 823-4127 Send $200 tsr complete catologueFax 604 823-4449 IMPORTED DIESEL ENQINES WORLDS UESTSflEC77ON AE AM Aurora Ceccarelh C4oolla FIT KMD MARS MA MOS MPJets MWS PAW Pfeffer Silver Swallow diesels Also replica Mills MOVO Letmo diesels well rare imported glow engines Ten page catalog $1 OO CARLSONANGINEIMPORTS 814 E Marconi Ave Phoenix AZ 85022-3112 Phone 602-863-1684 Afternoons wax trim until have perfect slightly oversize pattern exactly what want wax pattern mounted sprue base plate surrounded metal can covered investment solution investment casting plaster similar plaster Paris slightly porous after drying allow air escape through aluminum forced have paint layer investment wax first make sure dont have holes voids surfaces After investment sets up hardens remove base plate hake assembly furnace about 6000F dries investment melts burns wax out leaving cavity force molten aluminum casting alloy several methods inject aluminum such centrifugal force vacuum steam done mold still hot prevent aluminum cooling too fast leaving shrink voids mold dropped water after aluminum sets up investment crumbles leaving nice clean crankcase requires minimum machining produce finished part case usually heat-treated before machining maximum strength stability Finish-machine part making sure sleeve bore square crankshaft dimensions correct fit shaft sleeve bearings little bit work gave crankcase now have obtain other materials machine rest parts crankshaft troublesome has have just right amount counterbalance keep vibration minimum has made out steel alloy strong enough handle several horsepower high rpm Its easy find high-strength alloys usually dont have-a reasonable fatigue life 20000 rpm doesnt take long exceed fatigue limit shaft breaks Some manufacturers made shaft out mild steel has very high fatigue limit surface-hardened some areas bearings wear Others have used alloys such fatigue proof steel reasonably strong has good fatigue strength Whichever use has machined precisely finishgroundmaybe chrome plated connecting rod has strong lightweight have good bearing crankpin end have tried methods materials obtain best long-lasting conrodeven using such metals titanium roller bearings usually come back 2024 aluminum alloy pressed-in bronze bushing bushing alloy critical bronzes too soft some too hard brittle Bill Wisniewski has good luck lately using high-silicon aluminum alloy bushing get sleeve pistonthe critical parts engine sleeve has have ports proper timing dimensions angles shapes must made correct alloy have used Naval bronze free machining brass high-silicon aluminum alloy good results bore has chrome plated ground honed proper tapered profile profile critical area engine gives goer dud Modern CNC equipment can grind very close dimensions know learn what best can duplicated dont have proper equipment measure such micron dimensions have guess rely feel good piston-to-sleeve fits believe pistons could stand some improvement though high-silicon alloys work quite well Russians use alloys much 28% silicon others contain 19-22% silicon necessaryjor good hard long-lasting surface importantly reduces thermal coefficient expansion piston matches sleeve operating temperatures Pistons machined out bar stock castings must have taper top sides match sleeve especially top stroke finish engine dont forget need rotary valve intake timed correctly high rpm head good-running combustion chamber high-performance glow plug would likely make investment casting backplate-intake housing too So isnt much making own engine like Carlos does right just told build got everything just right would run good Next column Ill tell about some methods Bob Fogg uses build carbon-fiber airplane shells Model Aviation wLr Phone 62 557-6654 Fax 62550-0454
Edition: Model Aviation - 1995/03
Page Numbers: 129, 130
CONTROL LINE SPEED IF YOU READ MY 1994 NATS REPORT about Speed competition Lubbock last July aware extraordinary performance FABS Team Bob Fogg Carlos Aloise George Brown III Howard Sheehan outstanding speeds result much dedicated work expertise member contributes share Carlos engine builder learned about engine treatment years ago teenager top competitor Navy Carrier event worked engines fathers machine shop learned sleeve piston fit important part engine work get maximum performance father pit man won contests SuperTigre 35-powered airplane won Nats year Carrier Event Director disassemble engine due protest another competitor time rules specified no modifications engines no grinding timing changes new-parts substitution Carlos just worked piston sleeve get proper fit allowable other competitor sure some secret filing grinding engine since outperformed drastically Other modelers like Bob Burch Combat George Aldrich Racing also knew fit particular engine improve its output Carlos took 19-year vacation modeling included five years Navy marriage kids things like started flying again decided build own engines designed ACE Aloise Competition Engine think built two 21s first 049s 65s thought would try give idea just much work build high-performance engine like ACE Nelson Jett Wiley First have have enough sense know design engine make drawings parts must know about design sleeve port timing valve timing materials would likely start crankcase several ways obtain blank casting hardest way make hog out bar stock like Charlie Legg does its much easier make patterns have sand-cast investment-cast going make production run might make cast-iron permanent mold small number good castingsyou would likely use investment lost wax method gives good solid nearly finished castings Carlos uses method Start making exact pattern what want oversize allow shrinkage molten aluminum metal wood plastic combination Put reinforcements bypasses fins intake exhaust ports Make two patternsone outside case inside shape Use cast female epoxy mold force molten wax outer mold easyits made halves split apart wax pattern comes outbut inside difficult inside core pattern has cylinder bore exhaust hole crankshaft bore intake opening bypasses bearing bores piece cant get out wax pattern either have make totally demountable parts unbolt another make wax crankcase pattern two halves lot easier have accurately join left- right-hand pieces together additional melted March 1995 129 Authors Class B model uses engine built using ST 29 parts crankcase Bill Wisniewski some hand-crafted parts Bill Nusz Slugger Brown take break 1994 Lubbock Nats Al Baker Sam Burke Bud Hughes background FABS team working ACE 65 engine after rotary valve blew apart during backup flight record-setting run ABBREVIATED 8414K 1/24SZ 1/lASS 1/B SI 1/6 SZ 114021 37Dollar1000Bat22920321o93266944132998 40VOOghI Core F40209203092660045 15Coo JN4D Jenny215183292465938 86 952. 27LIodheog 802111591434 92469934 91948 29Wato TapooW1ng159142292045346048p062 36Westlod Lysander259183792475300 2 35 DOll 046A 0440 23924 34932 6894629 Boe ng 100 Spool 15916 224924 45 361609909 9 33StIn TrIeotoo30930459389062120 7 39Intl LI p382719392678 45 39Coo P3 F ghto18415282056 34 I2956 25Vgt Coo 0201/4182022854 44089 38COn Catina P05552487860 19CorEl. 814624669489 17FOkI0o 07 Fto14122116 930o4949 31Boyle GeeBoo1149121741435932 494470956 13Seprrlee S6E15$i022491364492660 3889 52 36Doe Gelfhawk14481421491843936SCALE P1414 35Lotk EletOro #1127925419325593BLook Elet 94 43Gem Arteger TBF3092840838.808 2Ford 314 4AT6 42Bee 1170 FlyFort5194077 95k00 1170 96 38MA l4itcIeell 82536483755 952A 025 96 34lAeoolCaetolOBZ72154815239224649351 14 826 6 37Coo Navy 003111981828492457936StIn Tn 4 25CBaoeo 1311 42118151649203BodlyPo o 6 34Doeg Toanep DC34794071 850oc Coot Hawk P6E15491523492267 4 4 32DoolIttlee GIfli12491718492237 3549 46 74958 31Roe 741364 P12815916224920444922594 64 89558 32Spofld RollDog1349162092040932S 8 32Homod Ike6lllike1048121549153192662945 34Tooner OW Rater13 $1219491639 285 90 7B952 35How ken ItellIgan1601523402047 3264 44 94 56 33Roe P26A Low Wog14$1521 20 423263 4584 58 35Stlneen TW SE720491631492562 4582 55 23 66 4208 8leeqeite Boeb37492441935 8150408965 37Stearean 711716 91824482249 3 30TABIG 8ke Tea13144 1321 1843 36860$ 438 Ilk WIdow 86133 O495099 75 42CHeIldIvr 0121425 82537 935 26Food Toleato 443883857 4814 72* 31RelIant Alo Roe3292248 3096 52 330ro J2F Dook19 2829 4058 558 68 27CSeehawk 771115 lB23 24 2801k Ah1b 03836 3454210 4 2 16IlPg 0400 Soak50 4575 56 31LIOdFe LSloIoe21916314 228 936 31Hoomod RtPete1O9121591530930 31C Spoohwk 79121248131992238 3550 8 7695B 33Aeroota 13 Spt1891027914534926107948 38looeero Poeto Ip12 81618 920379364994917449 03WeIght FlIer20 1830 24604038 READ BEFORE OBDERING*328 SCALE 1132 SIZE 1419818MM ORDER915 ooPLANS AVAILABLE AT ONE BE SURE TO AD T8E 800- DOLLAR UNDERUD4 SIZE AL 10Z FOR FACKAGING PRICES FOR ALL DESIGNS FOOTAGE 4210 IBSOSA5lCE T T8000ANO A001TIO8AL FLANS MANY SIZES e SOc975 CATALOG 9200 OR FRICE LIST ALONE 91SY___________________________________ AIR FOREIGN 93 LAND HI10 Bowman HIC Arcra Giant Scale Plans 28% Ultimate Biplane 3200 us 30% Ultimate Biplane 3500 US 33% Smith Mini Biplane 3500 us 33% Extra 230 available soon.. 3500 US prices include shipping handling "We FIq WhatBowman R/C Aircraft ilesiQn"41212 #3Rd YaFFow BC Fiberglass CowlsCanada VOX 2A0 Wheel Pants Gear Etc AvailablePh 504 823-4127 Send $200 tsr complete catologueFax 604 823-4449 IMPORTED DIESEL ENQINES WORLDS UESTSflEC77ON AE AM Aurora Ceccarelh C4oolla FIT KMD MARS MA MOS MPJets MWS PAW Pfeffer Silver Swallow diesels Also replica Mills MOVO Letmo diesels well rare imported glow engines Ten page catalog $1 OO CARLSONANGINEIMPORTS 814 E Marconi Ave Phoenix AZ 85022-3112 Phone 602-863-1684 Afternoons wax trim until have perfect slightly oversize pattern exactly what want wax pattern mounted sprue base plate surrounded metal can covered investment solution investment casting plaster similar plaster Paris slightly porous after drying allow air escape through aluminum forced have paint layer investment wax first make sure dont have holes voids surfaces After investment sets up hardens remove base plate hake assembly furnace about 6000F dries investment melts burns wax out leaving cavity force molten aluminum casting alloy several methods inject aluminum such centrifugal force vacuum steam done mold still hot prevent aluminum cooling too fast leaving shrink voids mold dropped water after aluminum sets up investment crumbles leaving nice clean crankcase requires minimum machining produce finished part case usually heat-treated before machining maximum strength stability Finish-machine part making sure sleeve bore square crankshaft dimensions correct fit shaft sleeve bearings little bit work gave crankcase now have obtain other materials machine rest parts crankshaft troublesome has have just right amount counterbalance keep vibration minimum has made out steel alloy strong enough handle several horsepower high rpm Its easy find high-strength alloys usually dont have-a reasonable fatigue life 20000 rpm doesnt take long exceed fatigue limit shaft breaks Some manufacturers made shaft out mild steel has very high fatigue limit surface-hardened some areas bearings wear Others have used alloys such fatigue proof steel reasonably strong has good fatigue strength Whichever use has machined precisely finishgroundmaybe chrome plated connecting rod has strong lightweight have good bearing crankpin end have tried methods materials obtain best long-lasting conrodeven using such metals titanium roller bearings usually come back 2024 aluminum alloy pressed-in bronze bushing bushing alloy critical bronzes too soft some too hard brittle Bill Wisniewski has good luck lately using high-silicon aluminum alloy bushing get sleeve pistonthe critical parts engine sleeve has have ports proper timing dimensions angles shapes must made correct alloy have used Naval bronze free machining brass high-silicon aluminum alloy good results bore has chrome plated ground honed proper tapered profile profile critical area engine gives goer dud Modern CNC equipment can grind very close dimensions know learn what best can duplicated dont have proper equipment measure such micron dimensions have guess rely feel good piston-to-sleeve fits believe pistons could stand some improvement though high-silicon alloys work quite well Russians use alloys much 28% silicon others contain 19-22% silicon necessaryjor good hard long-lasting surface importantly reduces thermal coefficient expansion piston matches sleeve operating temperatures Pistons machined out bar stock castings must have taper top sides match sleeve especially top stroke finish engine dont forget need rotary valve intake timed correctly high rpm head good-running combustion chamber high-performance glow plug would likely make investment casting backplate-intake housing too So isnt much making own engine like Carlos does right just told build got everything just right would run good Next column Ill tell about some methods Bob Fogg uses build carbon-fiber airplane shells Model Aviation wLr Phone 62 557-6654 Fax 62550-0454