Scratchin a Great Planes Super Kaos .60!!!!

[JoeMacD]

Well i dont know what happend to my original Thread but It gives me a chance to start all over again. This is the Great Planes Super Kaos which is no longer in production at this time. I recieved these plans ten years ago at a club meeting and decided to start this project.Since then I have built and flown the one pictured, and it flies Great. Now I am building a new one for a fellow flyer and will document the build. I am not using the original air foil,but I have modified it with the help of friends to a NACA 0014 air foil.It truly makes a world of difference.The plane is fast and stable and lands like on auto pilot.Hope you enjoy the pics as I enjoy the building.Please if you have any question's don't hesitate to ask. :wave:

[JoeMacD]

The building starts! Here are some of the sub sparts cut out to make the fusealage.since the sheets of 3/16 balsa was not long enough i had to join them to the needed lenght,i used a dove tail joint and reenforced with 1/32 ply skin on inside of former.And then the tail sufaces were made.

[JoeMacD]

Then the motor mounts were cut.Due to the fact that the nose wheel and the steering mechanism is inaccessable after completion, It is now time to mount the nose wheel steering hardware.

[JoeMacD]

Its now time to set up the fusalage.Formers are in place along with engine mounting beams and the firewall with nose gear.

[JoeMacD]

The tail surface is aligned and fuse top assembled on to fuselage.:wave:

[JoeMacD]

A look at the engine and fuel tank compartment.Remember to pic your balsa to the area where it will be.Meaning,try to use light balsa toward the tail of the aircraft and keep the heavy stuff up front but keeping in mind structual integrity.also Here is some shots of the wing ribs getting cut out and ready for that segment.

[bulletbob]

Joe looking good.Are you still building it or did you finish it?

[Gerryy]

Nice work, I had converted the original Joe Bridi Kaos to CAD and built it as the CAD Kaos many years ago. the plans still float arouund on the web. I built two of these 60 size planes and think it is one of the best planes ever. You'rs should fly just as well. I used an Adjust-O-Jig to build my wings.
GY

[JoeMacD]

Yes Bullet Bob I'm still Building it ! its been a while since my last post as life has its piorities,My inlaws have been sick and need the families attention.But yes its still on the building bench and will be finished before another project gets started.

And yes gerry I truly believe that this is one of the best designed planes ever, it really delivers outstanding flying characteristics.

[JoeMacD]

Now getting back onto the work bench I started to frame up the wings and i'll try to explain the pics in order!
#1)The plans show only the right wing. I will build both wing halves up side down due to the fact that when the wings are joined they are joined totally flat on the top surface to one another, this produces the dihedral on only the bottom surface of the wing!In the pic is ribs 1 and 2 of the right wing on the top spar!
#2) also showing ribs 1 and 2 but notice i laid them down in the #10 and 9 position.
#3) all 10 ribs now installed on top spar.
#4)now the bottom spar is installed.
#5)both wings now glued to spar! left wing was aslo built upside down with the the #1 rib in the #1 position but up side down.
#6) shows the ribs being eyeballed checking the alignment of all the ribs,looking nice and straight!.

[JoeMacD]

Pics 1 &2 )show me checking the end of the ribs for trueness! one or more ribs may need sanding to make sure the ends sit true on the trailing edge when glued ,also you can add shims if the rib may be too short.All ribs must touch the straight edge with out and gaps.
#3)The trailing edge startes as a 3/4X 1/4X30 stock.Then I draw a center line straight down the center ,then marke from the plans the spaces for the ribs.
#4)The ends of the ribs are glued one by one centering the center line on the rib to the center of the trailing edge.
#5)shows the ribs still nice and true with no ribs out of alignment.

[JoeMacD]

#1 )shows the same technique as the trailing edge done to the front leading edge of the ribs.but for this i first use a 1in wide by 30in long by 3/32 piece of stock with a center line down the middle.its easy to get your initial alignment of the ribs for later when you glue your real leading edge on.
#2) also checking alignment of ribs for trueness.
#3) so far so good framed up right and left wing halves laying next to one another.(Caution!!!! try not to make 2 right or 2 left wings!) Till next time Adios Amigos!

[JoeMacD]

Now I shave down and shape the Trailing edge and the what I call the False leading edge in preparation for top sheeting.I shave down and sand to the airfoil shape of the ribs.I use a straight edge across Laying it across the ribs and use it as a guide for trimming,then I sands to shape.Then I install balsa blocks to support the aileron hinge.I like using dubro or robart pinned hinges(my prefrence).Then I install the pre cut rib doublers for the landing gear blocks.

[JoeMacD]

Then I cut the holes for the aileron servo lead tubes. I like using the cardboard tubes or rolling up some paper stock. I made a Hole cutting tool from large size brass tubing.I sharpened the edges and cutt some slots in it with my razor saw. Then by hand rotate the tubing and slowly apply pressure to the rib and cut my hole to almost exact dimension of the tubing.I make the hole all the way to the #6 rib as this is the location of my servo. Patience is needed as you cut through the plywood doublers.I had picked up some cardboard tubing at the WRAM show one year and have been using it. Its from "The Aeroplane Works",as you can see in the pic.:teacher:(note) you must leave room for the Shear webbing on the wing spars when you cut the holes for the tube.

[JoeMacD]

Here are the pics.

[tandemairbike]

The Kaos is one of the all time greats.
Bob Machado, a peresonal friend of mine, of Ramco Models started his business in the late 1960s making ARF Kaos .60s out of all foam. Outstanding airplanes.
He then went on to design the First Step, Second Step trainers and the
Two Step biplane which he marketed under the Ramco brand which was later purchased by Great Planes.

I owned and flew one of his Kaos.60 models and it was a great flyer.

Tandy

[jimmac2]

Hi Joe,
Congratulations on an excellent build thread how far do you have to go to finish the plane.The plane in your first post is absolutely fantastic is it a kit build as well.
I am following this build as I am going to introduce it to a couple of the senior guys in my club as a good example of what they could be building and be able to fly without buying ARF's which fall to pieces on a hard landing and which has a proven good track record in the flying dept.
With your permission I would like to collate all your photo's onto an SVCD for presentation at club meetings to show them your working methods, which will also help new guy's see how a build goes and what they should expect to see beneath the sticky back plastic covering on their ARF'S when they bend them.
Yours Jim McGlynn.
www.modelclub.org

[JoeMacD]

Hello Jim very Pleased to meet you! Thank you for your Praise.The Kaos pics in my first post is the plane I am currently flying and was also scratch built just as you see in my pics on my new build. It fly's as good as it looks on rails and has unlimited vertical and can crawl in for a landing it is that gentle! I dont mind at all if you want to use my pics for club education, as i like to stress also the skills of building versus ARF.I'm not totally Knocking ARF's as they Have come a long way and are of high quality today! I personally think it is personally benificial for Pilots to build a few planes from scratch or from a kit and fly what they build.
I have more pics to post but I need some time to do it ! Will post soon !

JoeMacD

[jimmac2]

Thanks Joe I will wait for all your pictures to be posted and then I will put them all on one disc as a slide show,I will let you know how it goes.
Jim.

[JoeMacD]

Here are some more wing pics and installing landing gear blocks.I cut and sanded a groove in a hard wood block using a long drill bit of the propper size and using some handy carving tools.sizing the groove to the 5/32 music wire from K&S.Then i bent the wire in a vise to the shape of the plans.

[JoeMacD]

Due to pic limitation i have to double post!now once the landing gear is set its time to add wing sheeting.

[JoeMacD]

moving along

[JoeMacD]

Leading edge installation and finishing the sheeting and cap strips.Also setting up wing for Wash out. Washout should be built in before final sheeting as this locks it in place.:wave:

[JoeMacD]

more shots, also sheer webing installed then trailing edge block is removed to show the washout sintalled in wing.

[JoeMacD]

the wing is the set up and joined then center cection fiberglassed with heavy glass and epoxy.the blocks supporting the tips are 3/4 '' HIGH.

[JoeMacD]

Wing tip blocks pre cut to airfoil shape the temporarily attached for shaping and sanded the removed carfully the hollowed out as much as possible for weight savings. Then re -attached to wing.I am making the wing tips over sized ,brining the wingspan to a total of 59 inches.

[JoeMacD]

I know things are moving a bit slowly but i'm movin my butt! :LOL:but Now ive installed the ailerons and servo's in the wings.I',m using Futaba S3004 servos here.Take note of the pencil marks on the cover.The servo scenter line is parallel with the trailing edge of the wing so the control push rod is at 90 deg to the trailing edge.

[JoeMacD]

now the wing can be put aside and back to the fusalage.

[JoeMacD]

couple more closing of rear bottom of fusalage

[Gerryy]

lookin' good! Take your time and get it right. A straight model will be easier to trim and will fly right! You're doing a great job.
GY

[CalmAir]

Your getting there. Lookin good. Keep the progress reports coming.

Dale

[JoeMacD]

ok got some more pics.Shown is the engine mounting!

[JoeMacD]

next is the wing mounting and setting the incidence at 1deg pos. to opose the 2 degree's on the engine mount. these measurements are to the original plans.The nose has also been filled in and shaped with balsa block.

[JoeMacD]

shown here is the shimming trying to get the right incidence.horizontal stab at 0 deg. fusalage at 0 deg. wing at +1 deg. with engine nose down at -2 deg.

[JoeMacD]

Once I got it right it was time for wing Fairings with Micro balloons and resin. I first put down some monocote as a parting agent.wide enough to get a nice wide fairing.I also want to try to extend it past the leading edge of the wing like a P-40 so i glued a piece of balsa that i will work in on the bellypan.

[JoeMacD]

Now time for the micro ballons and resin, mixing to manufacturers spec ,adding enough balloons to where its kinda putty like and not runny!I made sure to get plenty under the fusalage to make a nice wing saddle.Then with a mighty blow seperate the wing from the fusalage and Walla! the perfect fitting wing saddle.then comes time to sand .

[JoeMacD]

and sand!I use like roof shingle grit 50-80 and some times wrapping it around a propotionally round dowel.

[JoeMacD]

With major sanding and wing blending done its time to sit back and think about the color scheme and final finishing. I ordered the rest of the servo's and reciever and covering ,also tires today.

[BigJim60]

I had one back in the early eighties & I loved it. I built it super light with an O.S. .61 FSR & it was a hoot to fly. I tried to find my original plans but I couldn't. I would love to scratch build another one like you have. I must have had a zillion flights on it. I ended up giving it to my neighbor & he sold it along with all his other RC stuff.
Good looking model you've built. I'm jealous of your plans. 8^)

[ser00]

Hi JoeMacD,
I want to say that your build is looking great. I too have the plans to the super Kaos 60, except mine say R/C Modeler Magazine. I too want to build this plane from scratch. Looking over your pics and my plans, I have several questions for you. First, when you cut the ribs out, you have extensions (tabs) on each end. How did you do figure this out? On my plans, there are no tabs (except they do have marks for holes for a wing jig). What purpose do these tabs serve? Do I need them to build my wing? Also, I noticed on my plans for the wing, there are blocks (No. 1,2,3) with differing thicknesses. What do these blocks do? Are they to set the washout for the wing? Any help or advice would be greatly appreciated.
Happy Flying!

[ser00]

Hi JoeMacD,

I have another question for you. I know that you are using a different airfoil than the one in the plans. Can you tell me how many degrees of washout are needed with the original airfoil for the wing tips. If you do not know, what do you suggest - 1, 1.5 or 2 degrees? Thanks a million!

Happy Flying!

[JoeMacD]

Hello Ser00, sorry its been a while since my last post i got involved with auto racing at a locaL OVAL TRACK. Thats were my summer was spent! going to get back to the kaos shortly.Well to answer your question, my friend had drawn the new airfoil with a computer program he as. I then drew the building tabs onto the airfoil section to allow me to build the wing in a mannor i'm most comfortable.The blocks in your plans will give you the propper washout needed to do the job.the Kaos should handle great with washout ranging from .5-2 degrees of washout.If your using the original airfoil stick to the specified block sizes. Everyone I know flying the original airfoil just loves it. i let them fly mine and they cant believe how much faster it is and it lands like a dream.hope i helped youe out there Ser00

[JoeMacD]

Now getting back to the Kaos.Ive been going over filling in any dents or gaps or holes that might be seen through covering!

[JoeMacD]

A few more. I dont know if I mentioned it before but the clear canopy offered by tower for there .40 sized UpRoar is almost the same if not bigger than the one I carved out for my first Kaos. About time to start covering.:)

[JoeMacD]

Ok covering has begun! Woo hoo !:D

[JoeMacD]

All covering will be done with Monokote!

[JoeMacD]

Some more wing pics!

[JoeMacD]

Now that the wing is done being covered time for the fusalage.

[affair]

I have been following your build with interest, its great. I have found the cad kaos plans so no I can build one! Can you say something about the airfoil shape you are using, is it fully symetric and just thinner? can I download it from somewhere? profilli perhaps?
Thanks

[affair]

I found the section on profili. It is symetric and does look thinner than the original.

[JoeMacD]

Hello Affair, Yes its fully symetrical Its the NACA 0014 airfoil. A friend who has a RC designer program for making all different airfoils was kind enough to Plot and photo copy all the ribs in the wing.Theres 10 ribs per wing.The plane fly great.Hope this new one handles even better. here are some more pics . Allmost there!

[JoeMacD]

Ok things are moving slowly now just as the economy!I ordered a tuned pipe and header for my O.S. .61 that will be powering this bird. and the tower .61 will be going back in the red white and blue plane. I just recently tinted the canopy with RIT fabric dye. I left it in a long time and got the results I was looking for. I then took black Monocote trim and cut out a black tracing of the canopy shape for the bottom, then glued the canopy on ,masked and flared the edge with Hobbico tan filler.Then sanded very lightly.Then applied yellow Monocote to finish it off.!:)

[JoeMacD]

found out the hard way that i misjudged the engine mounting holes with the spinner, so i had to move them back. i epoxied dowels in the holes and redrilled.I got the tuned pipe and the header and spinner in the mail and set it up tmporarilly to see how it looks. Awsome!header is long but must be cut to around 3 inches for this engine according to Macspro!

[JoeMacD]

Getting closser to finishing! i cut the header down leaving enough to play around with tuning.Then all i have is the control hook ups for Elevator,rudder, thottle and nose gear.Woo Hoo! maiden flight just around the corner.on the bench she looks fast. oh thats a pattern Prop 11X9 apc.

[affair]

Have you flown it yet?

[JoeMacD]

No I have not Flown it yet as i'm waiting for some spare time and some good weather to propperly tune the engine to the tuned pipe. Then i will bring it to the flying field and properly perform a maiden flight.Oh and also I'm waiting for a 6 volt 2000 ma battery pack, to set the proper CG with the tuned pipe and all.Hope fully i'll get some maiden flight pics and post them.

[affair]

I got the CAD Kaos plans off the internet. These are supposed to be a copy of the original design (one of the thread posts mentioned them) When I draw in the naca 14 airfoil (Actually I am using selig 8035 which is almost identical) I see that the point of maximum thickness is forward of the original airfoil. This suggests that the CG location might need to move to compensate for the difference, What CG position did you fly the naca 14 model at?
Thanks

[JoeMacD]

When Balancing my first Super Kaos I started at where the plans Indicated at about 4 1/2 INCHES from the leading edge at the wing root.Then after flying and By moving the battery pack toward the tail Gave me the the groovy feeling I have now. At 4 1/2 inches it was a bit nose heavy.

[JoeMacD]

Well yesterday was the day I fianlly got to the field for the first time this year and I Got to give my new Kaos a Maiden Flight and man is she fast And flies Great! Here are some shots from the field. I had to tune the pipe before going up then I was a little lean and it went dead stick on me .After richening it up on the high end I trimmed it out . Using the CG at 4 1/2 proved it was a bit nose heavy so i'll be rebalancing it. The third flight was all fun. I got to do many touch and go's one after another. She Stalls very preditable stright forward with no tip stalls.Like my first on this one is gonna be alot of fun.