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I love your detailed review of the testing methods and expectations along the way indicating where the reliability of the tests are limited. This is a great video on the forensics as well. Thank you Leon for putting this together

it would be nice to see a video on the Design of the press table once it's done. something like that would be really helpful to people who otherwise see formed parts as too costly. it might help people make other things more affordably and open up new avenues to them.

This is a critical aspect of aircraft design people almost never show. sure, we see full wing assembly load tests, but not individual component testing, and definitely not a test like this with nonuniformly distributed loads on small parts and small sub assemblies. Thank you for doing this and sharing it.

can you elaborate the formula used for Schrenk Span Dist.

Is it possible if you can share the dat file of your aerofoil?

YAY! CONGRATULATIONS on this fantastic test Leon! 🎉

The Scholler's are my kin, and from Oshkosh.

The only real test that needs to be applied in connection with any "ultralight" is whether your life insurance policy is paid up.

Great video showing all the steps. Thank you for not using time lapse - with this you often can’t see what is actually happening. And also thank you for not adding distracting background music.

Can't wait to see how this does in testing.

Excellent video detailing the fabrication steps and process, including all the little steps and details others gloss over.

Great idea and video! Would it be possible to account for the extra 8-11° in the original press form?

Allo , I am trying to find that surface primer in your video. Can you tell me where it can be purchased, Question; This stuff can be sanded to make Styrofoam smooth for a mold creation, yes? Thats what i need/looking for Thank You for any suggestion & this nice video

55 onot limit on max speed alonf with the 254 lb weight limit are some of the stupidest regs ever introduced by the FAA. STALL APEED IS perfectly acceptable byt the weight limit just invited fragile construction.

you could use a mylar film on the table as a release agent instead of the PVA, leaves a super smooth finish

That turned out beautiful! What material are the blind rivets? What diameters were the rollers that you used to form the skin? Thank you for the jump cuts! 💖 Sped up footage also works if that's easier in post 😉

WOW!!! GREAT IDEAS, LEON!! THANKS, FOR SHARING!!!

Another question for those that have had their RV's there for more than a few days. I see you can pay for a mid week on site pump out service, but there is also a dump station. Is it practical to put in slides and just drive over and dump tanks, refill water mid week and get back to site to finish week or is it always a huge back up and too much pain. Can be later in day when arrivals are slow, just an idea so we dont need to spend a fortune on on site services. Thanks

Really great analysis for the above average home builder. It would be great if you could do mathematical structural analysis for wooden aircraft, and for the wing section from the root to the wing struts. Also one for wire braced biplane wings

Thank you for all your videos you’re cool

What you’ve done creating the initial form is excellent but you need to be aware of a tool known as a “shrinker”. Also, the proper hammer and dolly technique can accomplish the same thing but is more of an art whereas the shrinker is a simple sheet metal tool.

Does it mean the normal flow media is too fast or absorbs too much resin or something vs the insect screen?

You have no idea how impotant this video was for me. ♥♥♥♥♥♥♥♥

Thanks so much for posting this- VERY informative for us rookies! 🤠

Hello I think that you have made a mistake in the chord calculation equation

Thank you!!!!!

Thank you for these videos very much!

If you cut a hole in the base plate under the 'R' you could have a bar run down to a foot pedal. With a little extra geometry, that could also power the compression for the bend. Much like a shrinker/stretcher in automotive body work.

So, given how much time you have spent forming this style rib, do you think this is still faster than building the rib similar to multipart Ultracruiser rib?

I'm loving your content, I'm interested in developing an ultralight myself. I want to replace a wood and fabric wing design with aluminum and fabric. Have you read "Sheet Metal Building Basics" from the EAA store? If not you should, lots of great information well presented. In this video you mentioned using 1/8" rivets through 0.016" skin. This is too large a rivet for the skin thickness. Chapter 19.4 states that the rivet diameter to thickness ratio should be no greater than 5.5, otherwise the expanding rivet will locally distort and buckle the sheet. For 0.016" sheet the largest diameter rivet that can be used is 1/16". See Table 2 on page 19-4. I have not been able to find 1/16" pull rivets so it will be necessary to use solid rivets. One other comment. A downside of starting with a large sheet, bending it, and cutting out lightening holes is that it results in the most scrap so it adds considerable cost (the need to buy more raw material for the same end result). While I agree that the 5 piece nose requires making more parts and using more rivets to assemble them, the parts start as straight rectangles that then get bent into shape so there is much less scrap from the raw materials. If solid rivets are used they are cheaper, lighter, and stronger than pulled rivets, but they do require different tools and learning the techniques to install them. If your ultralight is going to be primarily aluminum then the one time cost of the tools will be small compared to the number of rivet you will need to set so using solid rivets where ever possible will ultimately cost less, be stronger, and weigh less.

Very cool! Thank you for sharing this. My experience with hydro-forming is that, yes, different thicknesses will definitely have different springback angles. For a given alloy and heat-treat, thinner metal is springier and needs to be over-bent more, while thicker metal is less springy and will come closer to just staying where you bent it. This makes sense if you think about it; When you bend something thick, the stresses that you put on the outer and inner surfaces are much higher (i.e. more yielding will happen) than when you bent something thin, if you think of it in terms of "beam height". Anyways... I'm a huge fan (currently also developing my own ultralight), please keep up the great work!

I wonder if you stuck something like a ring sizing mandrel on the outside or " feeder" side, it would take a flat slat and begin the curve on a consistent basis.

Thank you

Thank you

Thank you for all work and dedication. Highly appreciated !!

7:29 I’m noticing that the laminar airfoil also appears to reverse its curves near the trailing edge so that the reuniting streams have a closer angle once they rejoin, probably inducing lower drag, perhaps similar to the effect winglets have.

Usually fly in and camp with plane, this year driving our "other rv" and have a decent solar set up, think we can live without air. I know the generators just scream, even in the just till 10PM areas, so thinking of our 32' rv parking in no genie area? Thoughts, think that would be a mistake? Sure would enjoy not hearing genies, thoughts?

Unnecessary part's and labor.

what are the design considerations required to design horizontal stabilizer in helicopter

You could have used bondo instead of drywall once you had the fiberglass over the foam. (I think bondo will attack bare foam).

For anyone watching, amine blush is water soluble. Use ample water and a mild abrasive (like a scotchbrite scrubbing pad) to remove it before sanding. Don't use alcohol or acetone or other solvents.

When you talk about maintenance these 2 stroke engines can fail very easy and also you may have a new engine but there could be a flaw with the metal use in the engine and it fails . I have seen ultralight aircraft were the wing brackets had big scratches in the corners I fixed it and the brackets that hold the rudder peddles on had 3/16 pop rivets in 1/4 holes and it was loose had to fix that and a few other things . Been an engineer if you have to do maintenance have a full check list record the maintenance and always every few month contact the manafacture or some that has the same plane and ask of any problems they have come across . And the way I see it I’m going to build an ultralight and I’m putting a parachute so there is the protection should something go wrong

I take it this video was taken the Sunday before the start of the airshow, right? People are coming in looking for spots, first come, first served on that Sunday?

hi. by any chance, do you have forum or group for ultralight design maybe on discord or something? thanks in advance

Given then number of changes you want to make/have made, are you going to build a 2nd model or re-build the first model to verify the changes or just assume they will be good?

this rocks! i didnt know you could use safety wire for this purpose

Add a turnbuckle to the tension cable or easier adjustments, and relieving tension for storage.

As you have intent to paint, instead, in your glass smooth mould, paint two layers of gelcoat in your desired color, then a 90gsm cloth, then two 200gsm, then a core with built in flow channels, then two layers of 200gsm.

Thanks a lot man

Great job but can you explain permitted and not permitted