IanJ's Marquart Charger build thread

Discussion in 'Marquart Charger' started by IanJ, May 4, 2017.

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  1. May 4, 2017 #1

    IanJ

    IanJ

    IanJ

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    This is a little bit premature, since I'm (still) waiting for wood to arrive from Wicks, but I am making slow progress, and starting to make things that are airplane-part-shaped, so I figured I might as well get it started.

    I've been writing journal/blog entries about the process so far, but haven't provided explicit links to them here yet. You can go to this link and see what I've written on the subject (this link will continue to be valid into the future):

    http://obairlann.net/reaper/blosxom.cgi/charger

    I will also post progress here, with Smizo's build thread as the model (though I can practically guarantee his work will look better than mine :D). Journal posts will be intended for a general audience, while this thread will be more technical.

    I've been generating some new lists, CAD files, and PDF drawings as I plan the build, and those are posted (or will soon be posted), along with the public-domain plans, here:

    http://obairlann.net/reaper/aviation/biplane/charger-plans/

    Rib wood should ship Any Day Now<tm>, and the spar order went through mere moments ago (expected in ~6 months). As soon as my order arrives, I'll launch into rib production, starting with the basic -293 ribs (16 required), and branching out to the different rib types as I go.
     
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  2. May 5, 2017 #2

    Dave Baxter

    Dave Baxter

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    Well good luck Ian, you have to start somewhere my friend. Dave
     
  3. May 5, 2017 #3

    Cameron

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    Looking forward to it.
     
  4. May 5, 2017 #4

    EAABipe40FF

    EAABipe40FF

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    Yes you have to start somewhere. Me, I started in the middle.......

    Jack
     
  5. May 5, 2017 #5

    smizo

    smizo

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    Enjoy the build...... every darn part.... hahaha!
     
  6. May 5, 2017 #6

    Taildragger

    Taildragger

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    Looking forward to this Ian. There aren't many Chargers being built these days!
     
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  7. May 5, 2017 #7

    IanJ

    IanJ

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    Today (still waiting for wood), I tried making a copy of my rib nose template, and discovered that it didn't copy quite as well as I had hoped -- the master is not quite square on the edges, and the lower capstrip space is a bit too large (.29" instead of .25"). I'm planning to get a bench disc/belt sander, which will allow me to make a new master that's more accurate.

    I bodged together a simple router table using some almost unacceptably rough plywood (I will probably replace that part, since it really is some awful wood), which allowed me to do my router practice tonight.

    The one completely fake rib nose I cut out of a crappy old piece of 1/4" plywood turned out very well, and leaves me encouraged that the process I've got worked out will do what I expect it to.

    I'm looking forward to being done with MDF soon, I feel like I'm covered in a thin layer of wood and glue dust after making three template copies with the router. I jigsawed them close to the line, but I still had to remove about 1/8" of MDF all the way around, and the whole shop had a coating of dust.

    IMG_20170504_212300-md.jpg

    IMG_20170504_212308-md.jpg
     
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  8. May 5, 2017 #8

    bdalporto

    bdalporto

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    Your going to love the Marquart Charger. Cartisan Tube use to supply Marquart frames. If you want to save some time you might give them a call.

    Brian
     
  9. May 5, 2017 #9

    cwilliamrose

    cwilliamrose

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    If you can find a scrap piece of Formica you can cover the top of your table with a nice, smooth surface.
     
  10. May 5, 2017 #10

    IanJ

    IanJ

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    Brian, I sent them an email a while ago, but heard nothing back. I'll check again, since I've heard such good things about the Cartesian kits.

    ...One phone call later...

    They have most of the files ready for the Charger, though it's not listed in their aircraft library. The guy I spoke to (Glen, I think) thought the fuselage kit would be around US$4000, and we didn't discuss the price of the tailfeather kit, but he's going to work up actual quotes and send them to me. Sounds like they're ready to go, just missing the machine instructions (which I'm guessing is not a big deal, since it should be auto-generated from the CAD files if they're doing it right). Interesting...
     
    Last edited: May 5, 2017
  11. May 5, 2017 #11

    cwilliamrose

    cwilliamrose

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    I'd price the raw tubing for the airplane from Spruce or ?? That way you'll know what those perfect fits and little or no DIY grinding is going to cost you. Perfect fits do make the welding easier......
     
  12. May 5, 2017 #12

    smizo

    smizo

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    In my opinion, if you can afford it there is only one way to build an airframe..... with Cartesian kits! So fast and perfect joints......
     
  13. May 5, 2017 #13

    Dennis Flamini

    Dennis Flamini

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    Chris,
    When you snap together a joint with a possible 9 tubes do you just weld the outer most joints or do you weld each of them all around?
    i decided to weld each separately on my motor mount.
    PS; did you ever figure the cost to build me a CF spinner from my mold?
    10" diameter x 15" long.
     
    Last edited: May 5, 2017
  14. May 5, 2017 #14

    smizo

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    weld around them all after the fit up. see other thread for spinner........
     
  15. May 5, 2017 #15

    IanJ

    IanJ

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    Raw tubing for the plane is about $2300-2500 depending on where I get it (that amount includes roughly 20% overage in anticipation of me messing things up).

    The Cartesian kit, according to Don VanRaay at VR3:

    So the Cartesian kit costs a bit more than 3x the price of the raw materials, considering that it doesn't include any overage.
     
  16. May 5, 2017 #16

    IanJ

    IanJ

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  17. May 5, 2017 #17

    smizo

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    Do they do an engine mount?
     
  18. May 5, 2017 #18

    freerangequark

    freerangequark

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    I spent a lot of time at the Cartisan Tube/VR3 booth at OSH last year. They do very nice work!

    Glenn
     
  19. May 5, 2017 #19

    IanJ

    IanJ

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    There was no mention of an engine mount kit, though I'm sure they'd make one up if I was interested. Apparently the work that's already been done was for someone in 2009 who then fell ill and couldn't build the project, so I'm sure that builder was just not far enough along to ask for an engine mount.
     
  20. May 5, 2017 #20

    JimC

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    Ian,
    Cutting and fitting the fuselage and tail feather tubing was one of the more enjoyable/educational tasks that I recall on the Charger fuselage I built many years back. In the overall scheme of things it is not much extra time. There are lots of different ways to grind/cut the various copes with low cost tools. If you have a rigid drill press, drill mill; hole saws work wonders. I have read a lot of the experts here do it with hand tools and a grinder wheel. I would consider saving that Cartesian money for the other jillion buy out items that you will need.
    My two cents.
    Enjoy!
     

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