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    533 views62 pages

    (Aviation) SNS-2 GUPPY Ultralight Plans PDF

    Uploaded by

    les5014126

    Copyright:

    © All Rights Reserved
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    of 62
    COMPLETE DRAWINGS OF THE SORRELL 3NS-2 "GUPPY" copyright © 1978 The enclosed drawings and information show the Sorrell SNS-2 “Guppy" as bullt by Hobie Sorrell. The drawings are true to the original "Guppy". Additionally, we have included the designer's ideas of suggested alternate materials or methods, in a few areas (listed as second cholces, or labeled "alternate"), The "guppy" is a very successful airplane exactly as it was built, and the alternates shown are only intended to reduce the cost or the difficulty of building slightly. are including written information to increase th: clarity of the drawings and to explain some methods of con- struction, This information doesn't cover every aspect of aircraft construction, but should make the drawings complete. Using these drawings and normal aircraft bullding techniques, you should be able to build a duplicate of the Sorrell "guppy". We suggest that you Join the EAA if you are not yet a member, as this organization and its! local chapters will provide you with lots of help and a wealth of information about homebuilding. ZAA makes available many books which will help with your project. CONTENTS Title Page Contents Butlder's agreement General airplane information General airplane description Engine description Alternates and Flying The Guppy side and front views top view general external information Fuselage Layout Side , Longerons and Vertical Members Note A Side, Showing Gussets Fuselage Structure, Top and Bottom Firewall Station #2 Bulkhead Wing Attatch Positions Layout Gear Box Landing Gear Cockpit Canopy Horizontal ana Vertical Tail Fuselage Controls Wings Fuel Tank Engine Parts Guppy Propeller For Cushman Engine General Construction Information Fuselage Construction referencing drawings General information referencing drawings Wing Construction A Wing Assembly Method Material Alternates Test Flying The Guppy and prototype performance Gushman Engine Parts List Limited Bill of Materials Photos Description Photographs Full sized wing rib drawing sas COVA FUE 14 to 16 18 & 19 20 to 22 23 to 28 30 to 33 54 & 35 36 37 & 38 40 41 & 42 AZ & 4h AS 46 aT Enclosed Enclosed BUILDERS AGREEMENT The recipient, by accepting these drawings, agrees to construct pieces for only one Sorrell SNS-2 "Guppy", this aircraft to be assigned sertaL #_19(, These drawings become a part of that airplane's permanent records. The recipient further agrees not to reproduce these drawings, except with the permission of the designer. It {s further agreed and understood by the recipient of these drawings that the supplier of the drawings and the designer make no warrantee, expressed or implied, as to the quality or safety of any aircraft constructed using these drawings. The above conditions extend to and are a part of any subsequent sale of said aircraft, whether in partially com- pleted or completed form, Sorrell Designer-builder Span Length Height Weight empty Weight gross Fuel capacity Wing chord Wing aroa Dihedral Incidence tagger Engine Horsepower Weight Displacement Fuel consumption Carburetors Fuel pump Magneto Propeller diameter Pitch Blade width Static rpm Landing gear Main wheels Main tires Main tubes Tailwheel Fuselage wings Tail Covering Other steel tubing SNS-2 "duppy" Hoble Sorrell ates Be 2h 31 Bn 3304 5754 5.5 gal. 36" (37" lower wing with alleron) 129 sq. ft. 1.5 inches each side 2 degrees upper, 3 degrees lower minus 11 inches OMG (Outboard Marine Corp.) Gusaman model 200 (4 cycle) 18 at 3600 rpm (redline 4000 rpm) 90# including prop, as converted 43.16 cu. in. 2 gph at 1/3 throttle cruise Mikuni (Yamaha) M 24-26 (2 required) (main jet is #56 drill, .046") engine driven (backs up gravity at low fuel) Fairbanks Morse CW type 20 FMX-1 2B7-1 (from a 2 cyl. Wisconsin engine) 4g" 9.5 degrees at tips, 12 degrees at 12" in from tips (non helical) 4 7/16 inches 3100 about Wittman steel rod type 5" magnesium "go-cart" wheels 5.00 X 5 tires (used Bonanza nose tires) 6" "go-cart" inner tubes 21/4 inch solid caster tire with a 1/4" pore brass bushing all wood structure all wood structure, aluminun fittings 4130 steel tubing 1.7 0z. dacron, lightly doped wing lift struts, engine mount, cockpit controls, windshield frame,and elevator push pull tube, wing tips The Guppy airframe 13 all wood structure, covered with 1.7 02, dacron fabric, with the following exceptions; the stick and rudder pedals, engine mount, windshield frame, and wing lift and Jury struts are welded steel tubing; the land- ing gear legs and tail wheel spring are 6150 spring steel rod; most attatch fittings (wing, gear, engine mount) are aluminum plate; wing drag member is a 3/4" X .058, 6061 T-6 aluminun tube; and the ailerons are sheet aluminum pop riv- etted to an aluminum tube. The fuselage uses "DeHavilland" type spruce and plywood construction. The wings are single spar with 1/32" plywood D tube at the leading edge, single strut braced. Wing ribs are solid sawed 1/4" balsa web with 1/8" x 7/8" spruce cap strips. The plana also show sawed 1/4" plywood and built up stick and gusset ribs as alternates to the balsa. The airplane was designed to approximately a load factor of 6 Gs. It should be flown as a “normal category" aircraft would be, to a flight limit load factor of 4 Gs, The Guppy is not aerobatic. The wings on the prototype are not designed to be fold- able. They are fastened on just like a T-Craft or @ Champ's wings. Any builder who wishes to build an ultra-light aust be very weight conscious, as pounds take away climb, The Guppy uses only normal building techniques to achieve light weignt and, built to plans, will be satisfactorilly light. Hobie estinates the cost for materials for the airframe at $500 "with a little scrounging" he says. Engine cost could be from $200 to about $900, depending on the many variables, Hoble spent about 750 hours building the Guppy, including time spent converting the Cushman engine. Many people have asked me about pilot size, I am 612" tall and weigh 165#, and find the guppy cockpit very com- fortable, It would’ accomodate someone bigger than I am. Ihave flown lt with a 200f load (me plus my 3 year old son) and performance was still quite satisfactory, although somewhat reduced. cockpit entry 1s accomplished by a step on top of the left wing root, and over the left side of the cockpit. The top and left side forward window hinges to the right, allow- ing easy access. The Cushman engine has proven very reliable and very satisfactory in 10 years of service. The airplane with the Cushman engine will outperform some well known designs with 36 hp. VW engines, The engine runs quite smoothly (about like a 65 hp. Continental) except at about 1800 rpm, only, it has a vi- bration zone. This is noticed only while taxiing, and requires opening and closing the throttle to maintain proper taxi speed on grass. It is not a factor in flight or at idle. I cruise the engine at about 3400 rpm. with the throttle 1/3 open, This gives about 65 mph. and uses about 2 gph. OMC Cushman is currently manufacturing these engines, and there should be used units available around the country. They are found in Cushman "Trucksters" and "Dumpsters" used. by police departments (metermaids) and park departments and post offices, as well as in industry for plant transportation. They are also found at large airports used by airline mech anics and service people. Write to Cushman Motors, Box 82409, Lincoln Nebraska 68501, for the name of the nearest dealer, if you could not find it in the yellow pages, The engine conversion 1s quite simple. It merely re- quires removing most engine accessories, (except the o11 filter and fuel pump) and fabricating the magneto mount, turning the magneto coupler and two carburetor adaptors from small blocks of aluminum, and turning a steel prop hub and an aluminum distributor shaft suport on a lathe, Carburetors are from a Yamaha motorcycle and use the gotoreycle cables, The nagnete is a conion Fairbanks Morse cylinder clockwise mit. The engine mount is made with 1/20 e O55 steel tubing and Cushman engine mount parts. It is similar to a Cessna 170 mount (only much smaller), Due to their location on the heads, the carburetors never ice up, We have never had any sort of problems with this engine. (Guppy has about 200 hours total time.) Alternatives Hobie considers the airplane sultable for engines up to 36 hp and 120f weight, 1f properly converted. (However, the Aeronca engines are awfully shakey, and 2 strokes are difficult to operate reliably.) He has started, and I hope to finish soon, a conversion of an Onan engine which is rated at 25 hp at 3600 rpm. This engine weighs 1# less than the Cushman converted and looks very promising, (Onan builds electric power plants and welders, among other things.) The old 36 hp VW engine could be used, but would require careful conversion to keep 1t light. Parts for these engines are available from J, C. Witney in Chicago. The previous two engines are the only ones Hoble wishes to suggest as alternatives at this time. These are only Suggestions, as the Cushman is the only one flown In the Guppy so far. The original Guppy 1s built with spruce and exterior 1/8" luan mahogany door skin plywood in the fuselage. Air— eraft quality fir, or upland or Canadian hemlock, and 3/32" marine plywood or 3/32" aircraft plywood are satisfactory substitutes. Flying The Guppy A few additional words about flying the Guppy may be useful, Please refer to ay article in the October 1977 issue of "Sport Aviation" for my original comments. The airplane is very controllable, yet it 1s not at all quick. It is definitely a rudder airplane, due to signifi- cant adverse yaw, and neutral stability in yaw, Dut because of its low speed, it 1s baby carriage like in its "aiffi- culty" rating. Installation of a skid bell is a big help in slip and skid control. (Hobie dismantled a turn and bank from an old Waco for the Guppies skid ball.) Several people have asked if there 1s any difficulty operating with no brakes, TI was also concerned before I first flew the Guppy, but I have since flown 1t in many different conditions (crosswinds, gusts, tall grass, pave- ment, soft fields, etc.) and have found’it no problem. When I first flew it out of Hobie's 900' airstrip, the air- plane presented no difficulty taking off or stopping. If I am operating on pavement, I don't land downwind, and if I wish to stop on pavement while taxiing downwind, I either put one tire in the grass, or turn into the wind, or I turn off the engine! There are no other problems as long as I plan ahead a little. The Guppy rates as a very easy airplane to fly and only requires the pilot to be gentle and modest in his demands. It will reward him with economical, useful performance. @ Serrall SNS-2. “Guppy” Seale t"-1' ooo ee Copyright 1978 { T tae | SF ste. Tai wee [eel spike | Pere KEE cable fey eens i ESR Great acer | Soot sre I Propeller: YS, S161 81 e0am line i —) Wi gate i | ee VY? Piet Tove es Tires 500%5 ae 42"Gap Steg Tobin g “ i ET FM) Engine Throat Line 5*Below + Parallel Te “Baton” Line is Petened Vu StqFeel Drain po bee (.032 Al) | #aF | 1p Faicing STFip { Ww. Sorrell SNS-2 “Guppy” Scale Te 1-16-77 Copyright 1978 Sersen Door Spring Section Sorrell SNS~2 “Gupp Fuselage Lay st (Dime s When FlaT) Scale Y= 1" or %eX%=1" Measure To Outside ExcepT Where Noted By @) aed _ Mote! Dim a in Bracket. {— $$ 8 Ald 4" To Dete —_________——6as Longeron Center Lin k—41%e | $a gap ;_ 94% 117 7 | aetna — M40" | jase Line ig z RK) 8 ¢ < © To Allow Bending of Top Leongeron Between @ And; Bandsaw ots Length- wise , And, Fill WiTh 35” Ply- wood’ Strips. vrawing ™ > Section Shoring Side,Longerons + Vertical Members Oe us spreee Wedges (Filler Blocks) Typieal ue Joints (Clusters) cise Center Lines ee ete eats Rel. Drawing * 5, It. Datom 2 (See Page 4) This creates 3° Incidence For Lower Wing STa. 2 Vertical Member, Bottom Layout Center Line || To Datem lot. 2 Vedat ISTa. 2 Verhical Member , Top This creal 2° Inciden.| For Upper W CSee Drawing? ) 13 To Baseline bo OS ee Deswinat 4 ) Section Showing Guss. 5 ($ Ply. Typ.) View of Left Side 34,028 The Left Side ‘Only Exh spree TrsTrvmenT Panel 18%—} 16 "Radivs Fill This GusseT With Sproce Wedges oO 69.08 los $40 ball Tach. Switch Mag’ Sw. (normally on) & Ply covers The inside of This ares, Forman oF sta. 2 Typical Gussel Arra (Inside Le age Fille Block own (Cackpit Tep Looking Doe sase 4) Deawing 10 StaTior 2 Belkh Note © HxEK 3g Sproce i Blo to Bring Strut to % Thickness (B places , Rear Side of B GaP, Becomes One $Sprvce Filler Dp EPL Fu34 Spree = Lower ™~ Longer £ Balsa or Foom fer ewes \\} $ Birch Plywood |Vrawing I Pgs oat, BY TYR | Tecate Ly —F Filings: 2 Wing oN luminum® @ Required BA 4 Top Feds od Rese E\¢ BTVPP | Rear wing Fitting a Washers 72 Al. 4 Required Ft Sp] eit on "Assembly "Final Drill ew ‘Assembly 1G X2 (Finish To Provide Stick Contre! Stop) 3K 3 "XP ole bal Lower Forward! Wing Fittir 4 Required fF Alumin All Wing Fittings Are B. and Eponyed pe In Place Drawing Wing Attatch Po. ions Layo Front Fiflings Kear Filtin Center Fron? Face Win: Botlom Line, Incidence gs Mteren 2° Upper 7 : 3° Lewer 20k Reference-Datum; Use Straight Edge Along Wing Bottem Da um Line Wings AttaTch With # Belts Rear Fitlings Final ———-20§3 —__>} Location Determined Front Fitting Rear, Fitting On Assembly To Achieve Center Front Face Proper £ ef Incidence * te Gear Box + Seat SeaT Cross SecTion Overall Size 13x24 C4" Thick Sandwich) Wing ED Balsa or Foam Gore Filler Block Under ' Rear Wing Fitting (To Achieve 205°" Be twean Centers of Fitting Positi. 5), (Also see below) Seat Back is B Sprvce Thick Sandwich, Around Wide, Held With $' 4130 Rod Threaded Both %Hre Seat Seat Bosh ok Cetnee 8 Seat Bo Gloed On y 4130 Red Threads Both Ends Ay povjg w Axed gpuw Log ae + £327) (leash pasmbay 2 Buryyry sore doy umeoys fy ways? bop 20D + Battie eal Patt reg Ax047 rey Poul seeg Sopery pay barry ty _ “6. 7 =o ey ze Pp ue y ee t= bay f pring) pombe 2 Uylig 4996) spleuy tt = 9e = —— ope + anhy go Coverteg 01 21 # kopors supey , F ' — Ke. 28.8 | Serge TT 7 en HH ob of (veg prea) paneto to wef Ura “ Grey ia oot po ditens [794 2g eo Mea eae Aas FL 1 FL 29S oapmera% samy eaK ree eat 7 folle a Be 7 10 Speers ye xk ket SF (Lr reL e492 Hed 21H dod, ted et M0029 »L4) Cyemyrey OS~ Sb OL L¥aL Leth’ Pueg oy TeoH] © uryreyd ras ree 0519 Brsods yr cat toy Gey Mtg Ferree weld cr bermese Drawing * 16 AW ERERS (0 Tailwheel And Spring Assembl, Screen Deer f b Spring For q eae Steering Tail - W heel Assembl Yar 058 Tebing cS Cross Strato 7 f For or bab 2b" Tire Vert. Stab An ora Atlateh 1Hxe Dovble Nats IE SH Tepiopan ae 2 Aircratt Eyebolts Feselage Opening Brace Tube $x,028 STeel Tubing (May Be Replazed With 5g Hj Sprece : Adegately Installed) )/4(open Width) x27" Plano 1} x,030 AL i Strip Over View OF Canopy Latch (Left Side) From Inside Cockpit 040 oH, th r,028 tube #x.035y Deawin Cockpit C4 Hinge, Al.Steips , And Plexiglass Fastened On Frame With Pop Rivets Frame OF £x.008 S Teel Tubing To Fit Fesclaye Opening feA.08) "Tobe Latch Handle 34.035 Tebex 2 Tep View OF batch Mechinism Onl Front Pin Slides Under Sg k .O40 Stee! Strip Bent fo Hat st Welded 6 sh (9) TR 4 Dia Pn Te Onletch, Slide Pin Forward —> Eod Altateh Fg. 6 Required 1040 Stee! Forward Horiz.Stab. Attatch Fig 2 Rea. a i" Steel ovrsde Washer Elevator Hern is 22” (Ele Center of Fle vator) Elevator Horn 040 Steel Dre ng # 18 “ail pris Stab Es Pineed * Above Top Longe + Evenly Belvern Vor Stab Front + Rear Spars. 040, Safty | Kudder Fedal (RighT) a Thinble Se oe Teco! 2 stick der ° mats | ec Aileron Horn 2 Required Micarla Tube Guide Locate On Assembh Typ. Elevator Red End Threpded Red Bind Insect emale Rod eles gx.o20%. (Or Fit Pilot) That? ry Tay, So ITT Rm leron Horns in ‘on e Tighe teams Gude $ x.035. soe a tunnel u Totel Ek Trav Elevator Tobe Is Aboot rn 108"(a') Long Cee ic Fabricate on Assembly . Fron'F “to "G" Is "OD White PVC Pipe Cable Guide Shewing Right Aileron Cable Stick Travel = Cal Draying® | é Wagers For Spacers Cater Pm Guide Tye. 24 "Pailey rey 7 PelleyHe Gone a pale Bee es : Mowat ing Pillow Block re? Aileren _ ve) Under Stick Opening 1 To Provide Stop BE Carhrel St Travel Up +Bown [60°F Elertte Pek 2 l|- Poll Tobi sel oonl aa 7 Pillow Ble, Va | abs: . G a 2% Cable Affateh fete A Cock, Conlre Steck | Exploded Views Note All Bolts In Cont Typical Pillow [ee be Ee | ace vice ley Ai 1h x 058 Tobin Maat” Be’ Drill. i" Long FN Belated Mots + Co Typical Ka cable 5 Cable Sikee (yer) Aileron Crank Side End 14p.058% "Long £ 4 $x 235, | 2 Te 4g Steel Side View Fr Without Elevator Crank Drawing 23 Upper Wing Panels 2 Reguived "Let T +R JOE LE Te Spar Front Face 42" Birch Ply Cor te Mahogany) A" Thick Ribs Between Leading Edge Ueding Edge top + Bethom (CED's Spar (ark SS + —t- repre! ort, | 4 phe \ hee $x§ Cap Strip’ Over|} Plywook, Taper |i Ends (12 places) |i H| gx af Spree He i | 1 |) oS BASS we Ps. Between Spar Ard TE. i] I Strot Froese 606) a Tylaces) || Rib Fe Al. Tobe Oy ade Eels Wing | (Leach on Drag Tobe mY N] wing Fanele WW (Fastined AT Eau! Filler Ble Typ calle DH pit Jonctore wi. Epa) Rear Fitling Hole (4*) Is 16” Above —— ing RIL Bello Line + Rear Elevation OF Spar x AF |. | this Fitting Upper Wings Ory (yi 6 ip Let Stout Fitting (aR eguired) 9° Soar Roat Fg. (8Reguired) Pitet Tobe 524 (Leet Wing Only) =) | 2 Require, eft» Right Top View Showing Limited Inner STrvstore “ 3x acon Strip Typicn Quer All Rest Ribs —— re Sproce Rear Falee Boney Buiiine — ore Rear False Spar SecT ion Lower Wing S Set Mig! Tobe Connection lit Ply + BAL. Both Sides OF Spar C€ Rib To Fair With %" False Spar Rear Het ghT. EAiTeron =F] Rear False ree CaM, O1G SheeT Al. For Good Rell Contre) Trailing Edge Most Have At Least $" Radivs et wv Inboard Section of Aileren >) linge Setup Typical 3 places Balk Wing Blacks Oboart Drawing ¥ 25 Debio cer Innery te STrot Fabeicated Eyeboll a B Bepeieea ee Required. ~ —_ Bes — 7 or Balsa Rib Only (Pl) Rib she 7H HY igo ste 4 Places. No Lightening Holes Under Sproce Double Cap Strips OnTop [gg " tu Heat Red, a ee Bend Eye ie IS,Sproce Beth | Hh get | rt _ And We Approx, |Single Cap Str * Together eee be baton’ P Fabricate 7 Gestion EY Interplane is To Bring I stret End Cotaway (1) StroTs Card) Bien a Fat Showing Eyebolt Relic A€ter fede Reet With FOPAI hing s Are seh Reliered Here oh Rivets Thee with Y Set Up. $F" OD Al. Bushings 2 Belial (is Weed Ply, “| eis] Ereboit |] eT Hole ny 8 ania t YUMMALLaL LA Hdyeur! a iTS Ss be Hx 4 Airerabt i Quality Fir Boshing wal. (Or Sprece) : Doble Cap Sho; Section E = Te ere ie Ply : InTerplane STrvt ib 4 Required 5 $uVerheal— ¢ Drawine # 26 - Zyt x Oo 2024T3 Al. Strip Wash Holes _- (fae ok Top Wins edo 32 Blom Ik : Wing) Doyble Cap Tre Sie 3B Spruce 1 Balsa Eis Normal Capstrip rein "Tete 5h Seu NTE | F8 tf Frnt Rear es Isa tenn Filler Makes Xo Cap Strip a a “_Y Rib Bottom Flat F Sproce Corner et ee ale Top View With Cap Strips Removed = At Hele Frio t #54. Sprece Corner Blocks PAT Cet beard Side Only oth C4, S * fe Tighiening, Holes au 4 TG Spree Typ. ees te REL Covered Wi Spae $" Marine Plywood 3} Lt V 7 fs ; i 1 a Leas” ep View With Ca Tri Wd : a Space For Hole Removed ae Remember To Dv After Placing Ese! 32 Phe pt Spree Fe Ply Typien! Al Types 7 Drawing LT b, As Installed LD Ore bet ax4 BxG Sprece Typ. O me Lr + Marks Aboot Where The Front Rib & ear Ri r re je: 0, fee ey foe Fey, Ribs yy Drag Strof Pases Throvgh The Rib (Typ. Al Rib Types; 3Places Typical @ Ply Gusset Vhere Dr wil BED pies Phe Rik GloeTo Kb + Epery Strut; Place on Boti Sides OF Ribs Typies All Rib Types. 2 Required Build After Selting Uo Toy Wings. eS ~----- TET Steet is 1" X.035 Steel ae Tubing “Stream ined MEP Jory finet Pty, 040 Stee! : re Bolt al san rappe: hi Tabric e4 i 4 cone Bel Asnted eth Blyccler Reuin ay Sicoh, le Bx ong sal S0T* Feds Cross Se: O€ STruT Sebo 1a" Leng Both Ends Flattened And Drilled For A 2 Keg. One On Rear O€ Each Top Spar Wing Deag Tube , Wing P 1 Support , Top Views Draw? # 28 Cp Wing) Batten Win pr2"Cap Strips — Wing Root Rib Face To The t Tt measores | 20" From Rew Face te Rear Face OF Wing Fittings | Bloe Around Rear Face Bre i Of the in nd Inside spar ALT Fi a OF Ribt Ke Goonter Sink | Catees Bross coellTe Foe Te FiowTo Terminate Drag Clyp 8 Places) + Bolt Hole 4. Gr 05809 BS coe Salad Gecko J, Slide 4" of FXOSB 606! To Al. tbe Tato Strot Ends Rivel In 2. Drill ZB Holes Cot Slot 3. Flatten Core Fully With Wood Hamner, Drill #% Bolt Hole On Assembly | Tube Drawing * 29 Fuel Tank Metal Tubing Shovld Be Blunted (Expanded) On IE" Plastic Pipe ddcntee The End Slightly To Hold SN poy nto Plastie Tobing May Be Fastened BEM 4 2 Bolt NK) 4 34x.032_/ To Inboard Lower Belt on Wing fitting Clear Plasi Fuel Te Clear Plas Fuel 7 In Cockp: | Foal Steel STrap (Friction Tare OD Devble Elk Under) is 2 Required O. Salovent Bulb + Smal) Hose Clamps Shutoff Valve BOD Copper Pipe Typ Or E quivelenT + Flare Filings Foto tape This T Replaced B x Fricfion Tape is eplaced By 3. 2 Elbows In Lone Tuo Threaded Outlets 77°79 Ie A Larger Engine welded Is Used Carburetor Adaptor 2 Required -- Aleminem ‘Magneto Adaptor i Praxis J Required --Alom nom [heart Co ioe Behe Dise $958 Tobing ach | Slot & Or. Disteibotor Shalt Supporl/ae 1 Reqeiced Alyminerm fro Bearing & [$00 Tot <—|]4 All Inside Corners 38°Radivs Except As Noted _ Drawing # IO Engine Parls Req ing Lathe b | NeTe Hy b- Lap Tap 1 Required 7 Tae Mild Steel toe Rear Main Seal Keepers 2 Requiced-- Use $" Drilled Head Bolts Drawing * 9! Engine Conv Engine + Magneto toons lace Over Ooller Part ce 3 (Engine Movnt) Place ots ci Typical Engine [ Attatehment/ Datem BxI4 Threaded — | Quart | Cushman Splitter ee Mel Oedled) Necdell Nenber | < 2EAL 4 Bradat Cok 2x it Bolr 4 \AiscnafSl 7ex 14 Bo Hr.058 ead Griled Head) [4 [eo9i74 } hans 4 [064734 js i: —| 4 |eove42 Sably Wire’! 4 ‘B0B8159 Fair bamkes Mage! These Bolt [4 | 60647. nh 4 3 pn Me eB a Hesiis Tgnition Timing Unilial); Impulse Snaps At TopDead Center 2 oFr— Top View OF cut And Re-Wold 8064493 Med iés: Here For Pre, ve for Prony 2e lone Paper Gasket Under, Cushman Part ts 160395 And 160396 Om $b ingoo493 This Hole Guppy Throttle Lett Side of Cockpit Notordyele Throttle Cable Parts Drawing Thre - e oe Drawing * 33 Enpine «ling (rie A Fabricate Cowl After _A Engine Installation, 2 , Make A Card beard Template To Establish 194 (Or As Engine Cowl Side “Radios Necessary To Fit Sides) Opening. 14° 2)” PianoHinge Beth SidesHalds Cowl beaiy K-04 >| Ye" Leng #6 Sheet Motel a Tate Weed tal "Where Al | CEI"? Fairings Fasten Te” Weed Strectore erat "Pk Screws Saree Hole Tinnerman Nite ao Fasten Inside OF YL eae” ye = Bottom Rear Is Not FasTaned, betsy > EK) | Geppy Pre Mer For Cushman Engine Stations (Also Inches From Cent Tip Tapered All Around G aa Mafe Tip Tapers os (ShewnAbet Ful 4% Cord Drawing * 22 Goppy Pro ler For Cosmas | Engine More Sections These Drawings And Dimensions Are Approximate NoTice The Bottom Curves Ovt About 76” Forward Thicknesses Ace 176" From Leading Ed, AEt Thicknessws(IF Shown) Are I7% From Trolling ay Notice This Propeller Is Nef Helical This Prop Is The Best One So Far For The Cush Leading + Trailing Edges OF The Prop (Especially The Ovder 6") Most Be As Shacp As Ts STrochurally Feasable. General construction information In these plans, the first listed material 1s true to the original Guppy, second listed materials are designer suggested alternates, All wood must be aireraft quality. All plywood 1s aircraft type unless shown on the drawings as"1/8 ply” only. This plywood can be 1/8" exterior door plywood (luan mahogany), or 3/32" marine plywood, or aircraft 3/32" plywood. Steel tubing shown is aircraft seamless 4130 steel tubing. Douglas fir,or Canadian or upland hemlock, are satis- factory substitutes for spruce if they are of aircraft quality. Fir 1s slightly heavier than spruce, however. Always use aircraft nuts and bolts, and always safety then. The cost of aircraft nuts and bolts is very nearly the same as lesser substitutes, and other hardware 1s not worth the trouble. Where specific material specifications are shown (ie, 2024 T-3 Al.), these are aircraft materials and specifications. The Guppy is covered with 1.7 oz, Stits Polyfibre using Stites materials thra the silver, then a light coating of butyrate dope. The fabric is glued on (no ribstitching). Hobie used Weldwood plastic resin glue throughout the Guppy, except where epoxy is specified he used two part, epoxy glue. All metal fittings, where they are against wood, are epoxy glued to the bare wood before finishing (in ad- dition to being bolted). Use cement coated 20 guage aircraft nails where required. Use 1/2" long nails through 1/8" plywood, 3/8" long nails through 1/16" plywood, and 1/4" long nails through 1/32" plywood. You can rip spruce members to finished size with a good table saw and either a Sears "Kromedge plytooth blade"(cat. #9-32448), or @ Sears "free smooth cut combination" cabinet, makers hollow ground blade (cat. #9-32644), This latter blade makes the smoothest cuts, but requires a perfectly aligned saw blade(it must be parallel to the rip fence). While building the Guppy be careful not to add any un- necessary weight, as only a few pounds decrease the perfor- mance noticeably. If you have questions, first double check the plans, as most information 1s shown only once in the plans, and not, always where you expect it (te, aileron control horns are with the cockpit controls, not the ailerons). Fuselage Construction Drawing Numbers 1 through 13 and 17 Dwg. 4, All layout work (fuselage and wings) can be accomplished on a 4 by 12' table, braced so it is fairly level and firm, Notice the layout dimensions measure to the outside of the longerons, and to the centers of the internal members' terminations. Dwg 4, 5, &6, Notes A and B show nonstandard ends of vertical members, In note A, ends become nearly vertical to conform to spar faces, Note B requires the forward vertical member top to terminate below the top longeron to allow room for the rear top wing fuselage fitting, See also dws. 10 & 12 for Note A clarification. Dwg. 6. These spruce members'ends conform to the spar positions, thus helping establish the wing incidence of 3 degrees lower wing incidence and 2 degrees upper wing incidence. Dwg. 7 & 8. All wood structure 1s glued and nailed in the normal aircraft manner, Small 1/8" thick wood sticks between gussets f111 the longeron outer edges and fill around openings to eliminate bumps in fabric. Dwg. 10. Note E means build the vertical member ends aft side out 1/4" so they are the same thickness as the cross fuselage boards. Dwg. 11 &13. The rear wing attatch fittings In the fuselage consist of a single 1/8" thick fitting at each of four positions, to fasten to the wing drag tube end. The top fittings are on the forward side of station #3 and the bottom fittings are on the aft side of station #3. The front faces of these fittings are exactly 20 5/8" aft of of the center of the spar fittings on station #2. Square 1/16" aluminum washers (dwg 11) are placed on the side of station #3opposite each respective rear wing fitting. Dwg. 12. Wing pin positions shown are accurate if the wings are built to the drawings; final holes should be drilled after your wings are built and checked for fit. Dwg. 13. Notice the 1" by 1" spruce longitudinal mem- bers on the floor under the seat (also see dwg #8). Seatbelt hardware is fastened to a lower rear fuselage wing fitting bolt. Shoulder harness should be fastened to an upper rear fuselage wing fitting bolt. Pitot tube, static line (run into a wing panel), and rudder cable guides are 3/16" inside diameter nylon’ tubing, available at swimming pool suppliers. Dwg. #15. Main gear legs and tailwheel spring are fab- ricated as follows; 1. Use 6150 steel (4340 steel 1s an alternate). 2, Machine part while straight per drawing (note, be very careful you have a smooth finish, and radius all corners, so cracks don't start). Heat red hot to bend per drawing. Heat treat to 45 to 50 rockwell. Main gear only; drill 1/4" top hole after heat treat, to establish zero toe in (eyeball axles parallel to lower wing leading edge). Dwe. #18 & #19. The simplest way to bulld the tatl hinges shown in the plans 1s to weld the 5/16" X .958" tubes to serap pieces of 9/16"or 5/8" tubing, then cut away all except the 1/3 circumfrence of the tube with the hinge attach- ed. Carefully weld this in its proper place on the controls! spar. The horizontal stabilizer can be adjusted with washers to trim in pitch. Trim for hands off with one half tank of fuel. Dwg. 19. Loop .040 safety wire loosly through the aft rudder cable end and the rudder horn eyebolt eye, for a fail- safe rudder control system. You could use plain 1/16" by 3/4" steel straps to attatch tail brace wires to their positions. The Guppy has a second electrical switch on the instru- ment panel marked normal (switch normally closed) and alter- nate. This switch disconnects the tachometer and the magneto switch from the magneto if a short should occur in the tach. or the mag. switch. TI have never experienced a failure of this type, but consider the switch worthwhile due to single ignition. The fuel guage is a section of clear plastic automotive fuel line. Fuel guage and tank outlet plumbing is 3/8" ID. Fuel line to the Cushman engine is 5/16" ID flexable tubing. Dwg. 24. The sediment bulb and fuel drain should be located as shown inthe plans with a Cushman engine instal- lation, as this is the low point in the system when the airplane is sitting on the ground, You may wish to make the fuel shutoff valve accessable in the cockpit, however the Guppy does not have this feature. You should not have more than one fuel shutoff valve, however. Dwg. 23. The wing tips are made with 1/2" by .028" steel tubing. They are attatched with wood screws at the leading edge, the Spar end, and the aileron spar. They are nested In @ round groove at these points. Glue a filler block at the leading edge to the outer rib, and provide the groove in this block, Provide grooves in the tips of the main spars and the aileron spars. The trailing edge of the tip tube, top wings only, 1s split and spread apart so as to fit around the wing trailing edge piece. At this position only, the tip tube 1s attatched with rivets. Dwg 32 & 33. The propeller shown in the plans is the best one tried so far with the Cushman engine. It 1s quite different from conventional propeller design, and 1s superior to more conventional designs which have been tried. The center of gravity with the pilot and a full fuel tank should be at the 30% of mean aerodynamic chord point. This point is 5.5" aft of the upper wing leading edge, with the datum (cockpit coaming) level. The cg must never be behind this point. The cg should be checked before flight by balancing the loaded airplane (pilot and full fuel aboard) on a sawhorse using a cradle under the bottom longerons. (Cut 2 2Xis, each about 3 feet long, so they have a curve which fits évenly under the bottom iongerons.) The original Guppy 1s built with no scarf Joints. All plywood joints are instead merely lapped. The laps are at least 12 times as wide as the plywood is thick. These joints, of course, may be scarfed in the normal manner. Dwg. 24,

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