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OV10's version of Foam 72" (1800mm) OV-10A Bronco build

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  • OV10's version of Foam 72" (1800mm) OV-10A Bronco build

    Hello fellow Squawk pilots/builders/modders,
    About 15 months ago I started on this foam project but it then got sidelined after getting the majority of the pieces together because the infamous garage inferno rebuild took priority. About a month ago I got going again and so here it is so far.
    Each one of those airfoil pieces(12) are made up of six individual pieces.
    There are two outer wing panels worth of top wing foils(6 per panel).
    Those top wing foils go to the outer wing panels of which the port is shown to the right.

    Click image for larger version

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    That is the bottom view of the port outer panel where the servo's and wiring slots and CF tubes
    got installed. That Dremel horizontal milling setup in the center view is a Dremel drill press
    machine that I clamped into a horizontal position used to mill out the servo pockets and other slots

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    So here is the center wing panel with all the airfoils glued on with Gorilla amber and the
    Foam-Tac Foam Filler/Finish process started.

    Click image for larger version

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    Here's the fuselage, right and center wing panels. The booms and tail assembly aren't shown.



    Here's the tail assembly. I used attachment tabs from the Dynam FW 190
    that was on MRC clearance. Using techniques for easier part assembly
    that I have plagiarized from Alpha's great efforts over the years



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    Wing joiners that I saved from my wrecked FW A-10 and modded

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    Wing joiners installed in starboard outer wing panel.

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    Port outer wing panel getting joiners installed

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    Center wing panel with flaps installed - top/bottom views

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    Port outer panel

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    Test fitting all pieces together

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    I'm 6'3" Wing is now ready for finish sand and servo/control horn&rod install
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    It certainly is a labor intensive process but is like the old scratch build days but with foam.
    It really reminded of how fortunate we are today to have the foam ARF's that get assembled
    in a couple hours versus the weeks/months of scratch build especially when time is such a
    premium in our lives today.
    But I guess we all now have some extra Corona stay at home time
    Best wishes to all for the near future and that's it for now

    Warbird Charlie
    HSD Skyraider FlightLine OV-10 FMS 1400: P-40B, P-51, F4U, F6F, T-28, P-40E, Pitts, 1700 F4U & F7F, FOX glider Freewing A-6, T-33, P-51 Dynam ME-262, Waco TF Giant P-47; ESM F7F-3 LX PBJ-1 EFL CZ T-28, C-150, 1500 P-51 & FW-190

  • #2
    Excellent work so far, OV10!

    Comment


    • #3
      Looking good Warbird and the best of health to you!

      Comment


      • #4
        Coming along nicely Charlie!

        Comment


        • #5
          Here's about another 12 hours of tedious (fun) work but it does make me really appreciate the benefits that the ARF foamie scene
          these past few years has allowed us especially in such stunning scale fidelity.

          The start of the vert stabs by checking horiz stab fit up.
          What you see is the 1/2 inch core of the vert stab.

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          Some foam wire carving and then elbow grease with the sanding rubber/foam blocks

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          Working the aerodynamic details. The core of the vert stab is 1/2 inch with 1/4 inch
          slabs laminated to each side. Used the bandsaw to rip the 1/2" in halves.

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          Fill-in work/touch-up using Foam Finish

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          And lastly, a finish sand and coat of Mod Podge Matte. It is an excellent glue/sealer/finish
          that leaves the surface of the foam resistant to dings and compressions.

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          Slowly but surely it is on it's way.
          Just a side commentary, back when the ProFly version was announced by MRC some folks on the Squawk where wondering
          why there was not a lot of zeal and exuberance from me and the bottom line is because I had this in the undertaking which
          happened to be at the same scale. I would like to possibly use the canopy hatch($85) and fiberglass cowls ($100) from the ProFly
          but am having a hard time swallowing the expense when that is 40% of buying the complete ProFly airframe cost.
          Warbird Charlie
          HSD Skyraider FlightLine OV-10 FMS 1400: P-40B, P-51, F4U, F6F, T-28, P-40E, Pitts, 1700 F4U & F7F, FOX glider Freewing A-6, T-33, P-51 Dynam ME-262, Waco TF Giant P-47; ESM F7F-3 LX PBJ-1 EFL CZ T-28, C-150, 1500 P-51 & FW-190

          Comment


          • #6
            OV10s coming back into service
            The aircraft, which haven't seen widespread U.S. military use in any capacity in decades, are getting a new lease on life.

            Comment


            • #7
              Looking nice Charlie. When are you going to Kit it.
              AMA 424553

              Comment


              • #8
                Great project CB, so good to see you back in action!!

                Grossman56
                Team Gross!

                Comment


                • #9
                  Been almost a month since an update but I have put another 20 hours of slicing, dicing and sanding.
                  The pandemic has been kinda second nature even by myself because of all the foam sanding dust.

                  Over on the Pro-fly Bronco thread I commented about using the 90mm YAK-130 gear for that bird.
                  Well the owners of that bird will be able to see from this fitting in the near future if they missed an opportunity.
                  I say missed opportunity because Freewing discontinued the YAK and I got lucky and got the last gear set from Motion.
                  Am using an E-Flite 110 degree nose etract which is the ticket for getting the nose gear tucked away nicely.
                  Plan to use E-Flite 90 degree nose etracts on the mains because I want that mount plate that doesn't require recessing
                  the etract so as to use a solid versus notched ply mount plate.

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                  Sizing the dado joint and angle for the nose gear

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                  Determined gear clearance hole, maybe do gear doors later

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                  Checking gear down geometry
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                  Checking gear up geometry, the 110 degree was the right choice

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                  Gluing up the fuse tail and then some sanding.

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                  Putting the butt cheek on.

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                  Getting the nose Gorilla'd on, luv that for structural strength.

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                  Got all the pieces laminated for the canopy, decided to go this route
                  rather than my original plan of dropping a C-note for the Pro-Fly cockpit.

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                  A couple structural bulkheads plus two mounting plates(1/4" Home Depot paint stir sticks) for the wing bolts.
                  Also got the landing light mount hole done with a forstner bit

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                  Canopy is sanded to rough geometry and fitted against the center wing

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                  The wing has it's base white coat because I like Alpha like the white wing with OD green fuse.
                  So my livery is gonna be that of VMO-2 when I'm done

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                  I hope to have the booms done and mounted on the next update
                  Warbird Charlie
                  HSD Skyraider FlightLine OV-10 FMS 1400: P-40B, P-51, F4U, F6F, T-28, P-40E, Pitts, 1700 F4U & F7F, FOX glider Freewing A-6, T-33, P-51 Dynam ME-262, Waco TF Giant P-47; ESM F7F-3 LX PBJ-1 EFL CZ T-28, C-150, 1500 P-51 & FW-190

                  Comment


                  • #10
                    Rc Castle still has stock of the Yak 90mm landing Gear :)

                    Comment


                    • #11
                      Have you decided on a power system yet? This thing ought to be feather light.

                      Comment


                      • #12
                        Twowingtj
                        That last pic of the center section fitted up weighed in at 3.5lbs. I'm calculating that AUW is gonna be about 10lbs.
                        Have had FMS Tigercat motors and associated props sitting in the wings for this project for almost 2 years now.
                        I bought 4 of those motors when I did and used a pair on the PBJ upgrade last year.
                        Warbird Charlie
                        HSD Skyraider FlightLine OV-10 FMS 1400: P-40B, P-51, F4U, F6F, T-28, P-40E, Pitts, 1700 F4U & F7F, FOX glider Freewing A-6, T-33, P-51 Dynam ME-262, Waco TF Giant P-47; ESM F7F-3 LX PBJ-1 EFL CZ T-28, C-150, 1500 P-51 & FW-190

                        Comment


                        • #13
                          Awesome work.
                          AMA 424553

                          Comment


                          • #14
                            How is it coming along with the build? Can't wait for a video.
                            Still Learning:D

                            Comment


                            • #15
                              Originally posted by Pauly View Post
                              How is it coming along with the build? Can't wait for a video.
                              Just about have the booms completed, probably another round of update pics in a week.
                              Warbird Charlie
                              HSD Skyraider FlightLine OV-10 FMS 1400: P-40B, P-51, F4U, F6F, T-28, P-40E, Pitts, 1700 F4U & F7F, FOX glider Freewing A-6, T-33, P-51 Dynam ME-262, Waco TF Giant P-47; ESM F7F-3 LX PBJ-1 EFL CZ T-28, C-150, 1500 P-51 & FW-190

                              Comment


                              • #16
                                Well that was a looooong week
                                It's been sweltering for our standards in temps here in the northeast so back inside from outdoor work and back to the build.
                                Had my every 2 month EGD from the VA this morning so no messing around other than to fiddle with the Bronco this afternoon.
                                Trial fitted the center wing and outer panels to the booms in preparation for installing the mounting hardware for the wing/boom connection.

                                The FMS Tigercat motors. And the verticals getting Gorilla'd to the booms

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                                Perfect fit to the booms regarding flap spacing.
                                Start sanding the booms later this week.

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                                Just showing off the salvaged/modified FW A-10 wing hard point attachments

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                                The hard work of fabrication is basically complete, now onto the tedious wiring task from the booms to the fuselage after the empanages are attached to the wing.
                                Getting closer to looking that it will be ready to fly this year
                                Warbird Charlie
                                HSD Skyraider FlightLine OV-10 FMS 1400: P-40B, P-51, F4U, F6F, T-28, P-40E, Pitts, 1700 F4U & F7F, FOX glider Freewing A-6, T-33, P-51 Dynam ME-262, Waco TF Giant P-47; ESM F7F-3 LX PBJ-1 EFL CZ T-28, C-150, 1500 P-51 & FW-190

                                Comment


                                • #17
                                  Another 6 hour effort to get the 90mm YAK 130 gear to the proper lengths and mounted. Glad am done for the day cause the work shop is now 85
                                  (add an hour also due to the trip to the hardware store for a busted 4mm x 0.7 tap but ended up getting a dozen 8-23 set screws and tapping those into the alum legs instead.)
                                  Used the main gear etracts that I salvaged from my wrecked FW A-10 2 years ago and the 110 Eflite nose etract as mentioned in post #9.
                                  Click on pics to view enlarged

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                                  Warbird Charlie
                                  HSD Skyraider FlightLine OV-10 FMS 1400: P-40B, P-51, F4U, F6F, T-28, P-40E, Pitts, 1700 F4U & F7F, FOX glider Freewing A-6, T-33, P-51 Dynam ME-262, Waco TF Giant P-47; ESM F7F-3 LX PBJ-1 EFL CZ T-28, C-150, 1500 P-51 & FW-190

                                  Comment


                                  • #18
                                    Man that looks great!

                                    Comment


                                    • #19
                                      rifleman_btx Appreciate ya poppin on here RM and viewing my slow progress...………...but hey, it's only been like 40 some years since I last did a scratch build.
                                      Warbird Charlie
                                      HSD Skyraider FlightLine OV-10 FMS 1400: P-40B, P-51, F4U, F6F, T-28, P-40E, Pitts, 1700 F4U & F7F, FOX glider Freewing A-6, T-33, P-51 Dynam ME-262, Waco TF Giant P-47; ESM F7F-3 LX PBJ-1 EFL CZ T-28, C-150, 1500 P-51 & FW-190

                                      Comment


                                      • #20
                                        Might inspire me to get back to my N9Mb project. Just lost interest for a while but I need to get back on it.

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