Gemini V2 UAV Build Thread

[Derek]

This is gonna be a bit of a slow start while I get more and more parts and pieces, but I'll post progressive updates. I needed two carbon fiber tubes (27mm and 25mm diameters) for the main wing spar, so I ordered those about 2 weeks ago. Surprisingly, coming out of China, they arrived yesterday. Quite happy with that. I also need twelve 1.2mm x 7mm x 1000mm carbon fiber strips to help reinforce sections of the main wing, vertical stab, and horizontal stab. I've ordered those today.....those are coming from China. I also need two 360 degree servos for the two FPV pan and tilt units. I've looked around, in all the wrong places, and found many servos that are $30 or more each. I really didn't wanna pay that much, so I kept looking. This morning, I found a company, in New York, that would sell me two 360 degree servos that are analog and metal geared for $17.76. That's a much better price....so, I ordered them.

I've decided to start the build with the tail section because I need to know the "finished width" measurement of the tail section so that I can be sure to build the tail of the fuselage so that it will allow the tail section to slide into the tail of the fuselage. I just got back from one of the local craft stores and I bought a bunch of balsa and basswood sheets and strips. I already have a bunch of 1/8" plywood, so I should have all that I need for the tail section.

I can't even begin to tell you guys how badly I want this plane, lol.

[Derek]

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I'm going to be honest with you all, lol...I've never done a balsa build before. It's a real challenge. I began the tail build, the other night, and I wasn't impressed with what I had gotten done, so I broke it apart and started over. The vertical stab was leaning to the right side. Hmmm, on a plane...that's unacceptable. So, the scratch builder, in me, took over, and I opted to use a bit of 1/2" insulation foam as a center core and I'll use that to adhere the balsa uprights to. Nothing is glued right now. It's just put together with two sided Duck tape and sewing pins (I love sewing pins while scratch building). I'm thinking that I'll get the foam glued down to the Rudder Shoe (that 3/16" plywood at the bottom), then I'll get the balsa uprights glued to the Rudder Shoe, then glue the uprights to the insulation foam, and then begin adding the balsa to the top of the Shoe that will add structure for the horizontal stab. I should be able to build the entire horizontal stab from balsa. Once I get the tail section all done, I'll begin on the fuselage.

[DOG]

Cool beans!. Your off and running "building actually" This looks like it's going to be your ultimate build. Good luck on the process and keep the pics coming. It will be very interesting to see how everything comes together

[Derek]

Thanks Ivan! Yep...it has begun! I need to make a run to the hobby shop today for some carbon fiber (and a few parts for another plane). I'll try to remember to take pics every now and then.

[Graham Lawrie]

I remember working with balsa over 30 years ago and it almost crumbled with a knife:) I think the key is to have good sharp very fine knives and be gentle:)

[Derek]

Im working on the fuselage now and Makayla insisted on helping......so i let her. I gave her a bit of a tutorial and now she's helping with the new build.

https://youtu.be/lsSxGsTyPyw

[DOG]

Hey Derek. Daddy's little helper. Next she'll want to fly. Too cool

[Derek]

If she wants to learn to fly, that would be cool!

[Graham Lawrie]

Very cool Derek:)

[Derek]

Thanks Graham! Shes great fun!

[Derek]

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Starting to see a fuselage

[Derek]

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[DOG]

That's starting to look sweet Derek. You're moving right alone. Thanks for sharing pics. Keep them coming

[Graham Lawrie]

Thats big:)

[Derek]

The finished fuselage will be about 70 inches long and the wingspan will be a bit over 3 meters

[Derek]

I got some time to work on the Gemini build tonight. In the following picture, you can see that I made two cuts into the vertical stabilizer and added two bits of 1/8" plywood. These bits are "T" shaped and will be sanded down to match the contour of the top of the vertical stab. These joiners have been glued in with epoxy and they simply help join all the parts of the tail into a single unit.....more strength. The two square holes allowed me access to the underside of the top of the stab so that I could epoxy some blind nuts, or T Nuts, into place so that the horizontal stab can be attached with two 10-24 cap head screws.

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The next picture shows that I have cut out the centers of the bulkheads and I have glued them into place. I used some 3/8" x 3/8" poplar on the inside of the fuselage to add rigidity and also to have more material to glue to. These were glued with a different type of CA glue that I've found but it's very similar. It sets in 30 seconds and is cured in 30ish minutes. Really great stuff.

bulkheads cutout and glued.jpg (87.88 KiB) Viewed 5776 times

The next picture, I'm just dry fitting the vertical stab into the fuselage. WOW! It just looks awesome!!! That yellow ruler is 36" long. I place a pop can at the nose. The second pop can is 24" back and the third pop can is 24" back from the second.

dry fitting tail.jpg (86.47 KiB) Viewed 5776 times

.....more to come....

[Derek]

Here is a bit of video of my 4 year old daughter, Makayla, showing how much of a great helper she is. This is no scrap piece of wood that she's sanding. This is one of the fuselage sides. She's so gentle but efficient.

https://www.youtube.com/watch?v=lsSxGsTyPyw

[DOG]

LOOKING GOOOOOD! That plane is going to be awesome Derek. Keep up the good work

[Graham Lawrie]

Starting to take shape Derek:)

[Derek]

Started the center wing section

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