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Old 05-14-2017, 02:21 PM   #1
Youngman1
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Default Carbon Fibre Heel Trays

Hi All

I'm about to make a pattern and mould for some carbon heel trays for my Laser project. I was wondering whether the size is similar to Pitts ones.

Does anybody have the dimensions to hand?

If there is good cross over i'll make a common mould and perhaps look at selling some.

Will be high quality Pre-preg so finish will be great. Not saying they will be lighter than ali but certainly no heavier, and if like me you can't resisit a bit of carbon bling then that's no bad thing!

Cheers


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Old 05-15-2017, 05:51 AM   #2
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How many layers of carbon do you want to use ?
For example,if you use 5 layers of 200 grams per square meter, you will have a part of 1000 grams plus 40 % of resine ,so a total of 1400 grams per square meter using the infusion technique. That's the lighter you can get.


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Old 05-15-2017, 10:25 AM   #3
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Quote:
Originally Posted by Jean-luc View Post
How many layers of carbon do you want to use ?
For example,if you use 5 layers of 200 grams per square meter, you will have a part of 1000 grams plus 40 % of resine ,so a total of 1400 grams per square meter using the infusion technique. That's the lighter you can get.
Thanks, tbh I know they will be lighter but wanted to head off any comments about it being a pointless weight saving etc you know how it goes

I'll probably go with 4 layers first and see how stiff that feels.

Do you have the dimensions for the S1-SS you're building?

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Old 05-15-2017, 04:32 PM   #4
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The ones on my airplane are made of 4130 steel. I am also considering switching to CF to save at least a pound. I will measure them next time I go to the hangar.
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Old 05-15-2017, 06:36 PM   #5
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4 x 200 grams will not be that stiff.
Have a look to that video
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Old 05-15-2017, 07:28 PM   #6
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OK, What you want is 2 plies of carbon, 1/4" Divinycell core, then 2 more plies. Put flox hard points where the screws will go through. And since composites are not very abrasion resistant, you likely want aluminum heel scuff plates. Those will need some hard points in the composite sandwich for where rivets will be squeezed.

Turn up the sides of the trays so that the top and bottom lamina together give you 4 layers on each side keeping your feet centered. This also closes out the sides of the core. You will want to alternate 0-0 and 45-45 orientations of the lamina on each side of the core.

Light and strong.

Best of luck,

Wes
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Old 05-16-2017, 02:45 AM   #7
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Quote:
Originally Posted by PittsDriver68 View Post
OK, What you want is 2 plies of carbon, 1/4" Divinycell core, then 2 more plies. Put flox hard points where the screws will go through. And since composites are not very abrasion resistant, you likely want aluminum heel scuff plates. Those will need some hard points in the composite sandwich for where rivets will be squeezed.

Turn up the sides of the trays so that the top and bottom lamina together give you 4 layers on each side keeping your feet centered. This also closes out the sides of the core. You will want to alternate 0-0 and 45-45 orientations of the lamina on each side of the core.

Light and strong.

Best of luck,

Wes
Thanks for the tips. I've got some honeycomb that might do the job for the core.

Anyone have any dimensions?
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Old 05-16-2017, 05:34 PM   #8
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I have carbon fiber foot trays if I can get to the hangar today I will measure them. They look and work great, I didn't build them so can't speak to their exact construction but they appear to be just layers of CF no honeycomb.
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Old 05-16-2017, 09:29 PM   #9
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Foot trays are 5 inches at the heel 6 inches at the toe, 17 inches total length, .1 inch thick


ImageUploadedByBiplane Forum1494970140.174654.jpgImageUploadedByBiplane Forum1494970152.811240.jpgImageUploadedByBiplane Forum1494970167.201068.jpg
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Old 05-18-2017, 04:51 AM   #10
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I would recommend against the honeycomb core. We had honeycomb core floorboards and while very stiff and light, the honeycomb would crush under the heals of heavier pilots. We replaced part of them with exactly what Wes describes, carbon fiber with 1/4" Divinycell cores.
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Old 07-17-2017, 11:58 AM   #11
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I have been building a mold for some Naca vents and have been enjoying doing the composite work. I plan on 4 vents for a Skybolt. Was thinking what other components can be made in CF. A plenum, heel rails, instrument panels.... then I start struggling on other components. I've seen the seat on here and whilst it's good - it's a lot'a work.

Any ideas on other non structural parts that make good candidates for CF?
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Old 07-17-2017, 12:23 PM   #12
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Cabane fairings

Gear leg covers.

Id love gear leg covers because aluminum cracks are annoying.
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Old 07-17-2017, 09:02 PM   #13
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Brake covers
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Old 07-17-2017, 09:26 PM   #14
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Extra gets $400 for one brake cover and about $2000 for one wheel pant. Benny Davis looks really good against that yardstick. There are opportunities for other motivated folks.

Best of luck,

Wes
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Old 07-17-2017, 09:34 PM   #15
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"carbon fiber with 1/4" Divinycell cores"

Divinycell H45 is good for 72psi compressive and weights 3 lbs/ft3 nominal
H100 is good for 239psi compressive strength and weighs 6.3 lbs/ft3 nominal

If you plan to fly in cowboy boots or high heels, go with the H100....

Best of luck,

Wes

Last edited by PittsDriver68; 08-01-2017 at 12:13 AM.
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Old 07-31-2017, 09:45 PM   #16
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Hey Guys

Thanks for all of the advice, just finished the first test piece. Pretty happy with it. It's very strong. Turned it upside down and takes my weight 85kg easily. And a smidge over 100g so not too bad. Just need to finish the edges and lacquer.
IMG_20170731_183314.jpg   IMG_20170731_183323_01 (1).jpg   IMG_20170731_183524.jpg  
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Old 07-31-2017, 10:01 PM   #17
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More pics
IMG_20170722_130417.jpg   IMG_20170722_180114.jpg   IMG_20170722_155111.jpg  
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Old 08-01-2017, 11:17 AM   #18
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Wow looking good!
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Old 08-01-2017, 11:36 AM   #19
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Very Nice!!!
I am not skilled about composite but would like to have the same on my S-2a...



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