Flite Fest Scratch F2A Buffalo

This was my first ever 'real' scratch build. I've previously constructed airframes off of a laser cutter, but few were ever completed to flying order. With that previous histroy in mind it's quite amazing how well this project turned out, and the events leading up to it's completion.

My first Flite Fest, I wanted to make it as fun and productive as possible. Tuesday night, the day before the drive out to Ohio, I decided I wanted to create a 45" warbird for me to build at FF, even if I couldn't get it to fly or even finish it. I've always recieved critical statements about my wanting to make a Brewster Buffalo at some point, so I figured it'd be ironic if that was to be my build.

DESIGN

So, I worked deep into the night. I started out by sourcing some good reference plans, and tracing them in Photoshop in order to single out what I want to design it from.

After I had the drawing all traced, I simplified it into its own layer and saved it as a JPEG. I then imported it into AutoCAD, where I scaled the wingspan to the desired 45" and traced out all the formers and control surfaces. I had to use the information provided by the cutaways and isometrics to figure out a good shape and size for the box I'd be glueing all of my formers to.

After trying to wrap my head around it, I finally got all of the dimensions figured out, and had the process all ready in my head. I got it all compiled into a four-sheet foam configuration, for future laser cutting possibilities. At this point, I started to get some hope about it flying, as the box was big enough for a power pod.

As inexperienced as I am, I was resourceful enough to divide up the plans into US Letter sized PDFs and printed them all out, as well as compiling them all together into one large printed sheet of plans.

I started to cut out some templates, as well as glueing the 'fusebox' and tail construct together for Flite Fest assembly. As I am too young to drive out-of-state, I had my patient grandfather driving us 12 hours out to FF, with a Storch and the soon-to-be Buffalo in tow.

CONSTRUCTION

After setting up shop, and soloing for the first time (yes, I took on this build before my first solo) I started cutting out all of the templates for the airplane, and adding the formers to get a good idea of the airploane's lines. She looked beautiful from the start.

I had way more progress than anticipated, and was almost at the point of covering her with posterboard. I had to make minor changes to the formers' geometry due to differences in the wing's shape, but I didn't need to make any compromises otherwise with her construction.

On Saturday, our last day, I knew it was crunch time for finishing the airplane, and I set the ultimate goal of getting her to fly before leaving. Sourcing the electronics from my Storch (it runs off of the C Pack) and some servos from the FT Store, I had her almost ready to run. I made a bit of an edit to get the pod to fit by cutting a hole inside the cowling for pod mounting, and removing two inches wide of foam from the upper layer of the wing, but it still held strong and ready.

I spent the afternoon sketching, cutting, testing, and recutting posterboard to cover the entire airplane. I took the opportunity of the absence of wind and decided to get her ready to fly without her tail covering (it wasn't necessary in that spot). I was very lucky to have met Sam Hince, who had constructed the massive combat B-17. We had talked over FIRST Robotics and his build, and he looked forward to seeing her fly.

When I had finished the Brewster, I took her over to Sam. I told him of my recent first solo flight, and he suggested taking her over to Josh to maiden it. I was taken aback by how enthusiastic he was about flying her, despite how busy I thought he must be, running around the event. His best words were "Can we still be friends if I crash it?" We tested the CG and she was perfect at 20% from the leading edge. (I used two steel plates in the nose to balance her out).

The second we launched her, it was up and going steady. Bix was having her doing rolls, loops and inverted before a single circuit of the flight line. No trim was required. He passed the transmitter and she flew like a dream. I had predicted that a mid-wing warbird would have very serious tendencies against a rookie like me, but it was fantastic! She flew on rails at half throttle, and you would never have guessed her full-scale background.

I had Josh 'sign it into production contract with the US Navy', which was pretty neat.

After getting home, I laid her out on the dining room table to finish her up. She just needed some tail covering. After some difficulty getting the paper installed on the servo side, it was 'smooth' sailing from there.

CONCLUSION

She flies fantastic, and was a great build to start off my scratch experience on. I had to modify a couple formers based on geometric size conflicts, but I'd just suggest that if you need to make any modifications, it should still come out just fine. The next build of it I'd do would feature less posterboard parts, such as covering the midsection as one piece and the cockpit as one folded piece, for ease of construction and replication.

If you plan on taking one into your own hands, just know that the most important alignment is that the wing is centered and that the powerpod and tail section is properly aligned. The wrap doesn't need to be perfect to fly well, I even had it maidened without any tail covering! She'll fly on a very bare setup.

I'll likely make a build video on how to construct it more in-depth, so look out for that in the future.

MODIFICATIONS

A 1/2" cut in the top of the nose about 3/8" from the front of the fusebox (remove the cowling section), with a C fold-style plate about 1-1/4" long for mounting of the powerpod. Base all other measurements (pod skewer placement) on where it lies from there. (Test fit the pod so that it is flush with the top and that the pod is centered, facing straight forward, and then make your side-skewer marks).

A 2" wide removal of the top layer of foam from the center of the wing in order to seat the powerpod, leaving about 2-1/2" left from the trailing edge, and 1" from the leading edge, inside the fusebox. (The new plans should have accounted for this).

SPECIFICATIONS

Motor: Suppo 2217/7 1250kv

ESC: Suppo 30A Brushless

Battery: 2200mAh 3s 20C

Servos: 4 x Emax 8.5g

2 x Servo Y-Harness

2 x 20cm Servo Extensions

MATERIALS

4 sheets 20" x 30" DTFB

1 sheet (2 recommended) 20" x 24" Posterboard

1 BBQ Skewer

PLANS

F2A CAD File

Full Plans A (First Half)

Full Plans B (Second Half)