The ever elusive Piper Cherokee,I've been about 2 years designing,building and starting over with this design.Truth be told,this is the 3rd version and hopefully the last.There is other projects I want to start.

So a little background first into the reason for this build.Ever since I came across Flite test I have been obsessed with Foamboard,it's remarkable stuff yet it has it's limits.Lets say this,it's not Balsa  or Depron but in my mind there's no reason why a build in foamboard has to look any less an impressive model.

There are guys here in the UK who build utterly staggering models in Depron

Yep these are both large scale Depron models,more can be found at 

http://www.modelflying.co.uk/forums/threads.asp?t=82&p=1

So my point is this,why are most foamboard models not like this ? 

Well obviously I know why but it got me thinking about producing a model with a higher level of detail and trying to take foamboard and pushing the limits certainly of my building skills.

I had to choose a model,something a little different.I prefer low wing models so I started looking for something to build.The Piper Cherokee was my only choice.That decided,a decent 3 view drawing was next on the agenda.

This is the actual 3 view I used to design the build in Sketchup.

Now my building process isn't quite as simple as using flattery in Sketchup,the render you see above was the 1st set of formers I produced and built.From there I test built and checked for any possible issues.....there were plenty.

1st issue was a major one..... battery access,there is no powerpod in any of my current builds.In a nutshell,powerpods and battery hatches by their very nature spoil the finish that can be acheived in any model,so how to overcome this rather major issue,well by using the one open acces that there is,the wing seat.

A standard powerpod is no use and there has to be room to position the battery for balance.....no small order considering I have been mulling this over for nearly 2 years over 3 different builds.

My solution was to take the battery box and turn it upside downand make the velcro for the battery positionable.

Happy with the concept I carried on to the next problem,the steering setup.This would require several ammendments in Sketchup.

The problem was how the linkage ran from the servo to the nose wheel,it's not a straight line and it needs to run through 2 formers.It was time to get creative.

Another issue resolved...only took several hours !

At this point I had figured out motor mount,steering linkage,ESC placement and battery access,time to print the ammended Sketchup file and build again.....

The above is a render taken from Sketchup with all the amendments made,time to figure out the skin.

I took an approxamation of the side view from Sketchup and allowing for the curves I knew I was wanting to make,added extra to the part and printed it out.If anyone has tried printing direct from Sketchup they may have noticed it's not the easiest of things to do taping it all together ! That being said it wasn't long till I had the 1st piece cut and started trying to figure out how to make the foamboard shape to the contours I wanted.

The nose was actually coming together nicely,it was the tail section I was having issues with.Didn't help that I made a mistake in the cutting of this skin.You can see above where the TE of the wing would sit I made a cut in the side to allow for the skin to taper back to the tail,that turned out to be a lengthy mistake.I spent at least a couple of hours trying to make the sides match up evenly allowing for the tail to sit in the correct position.Turns out the fold is actually in line with the last former,not where I made the cut.

Measure twice,cut once !

Lesson learned there.....again  !

After much fiddling and fussing,several days ....and copius amounts of coffee,the skin was figured out.I will cover the wing seat later in the article.

Tail surfaces were my usual,double skinned with equal throws,same as all of my builds.

I had made all the adjustments,corrections and ammendments I could think of,it was time to build a prototype.

Plans printed again straight from Sketchup I noticed a possible mistake waiting to happen,long thin parts cut out have the chance of being pulled out of alingment when you're transfering plans to foamboard,just one to watch for ! anyway.....

All internal formers

Prototype adjustable battery box.

Assembly of formers and runners

Steering linkage

Motor and firewall

ESC placement

Ready fro the skin

Skinning the fuse.

Before I can skin the fuselage,I build the wing center,this is always one of the 1st parts I make in any of my builds.I use it to check the fit of the runners,formers and to outline the profile in the skin.It's also handy for sitting the model on while your working on it .

One of the sides,notice it has had bits added to it ......it wasn't big enough.

Skin positioned and wing center added.

At this point remove the formers etc and draw around the wing center.

Reposition to check fit and alingment.

I build using Westfoam foamboard,there is zero chance of removing the paper so it needs multiple cuts to allow for curving.

This is where all that extra work shows,what a great fit !

control linkages were installed at this point,I used  Sullivans Gold N Rod,very nice piece of kit.

The rear turtle deck was one part of this build I had a very specific idea for.I wanted it to be as seemless as possible mainly to accomodate the strip that runs down the center of the windscreen,

Starting at the tail it is very much a case of marking,measuring and cutiing/trimming till the desired fit is achieved.

Once the fit is good,lots and lots of 50% cuts to allow the curve.

Final trim ready for fitting.

Joining the 2 togetner takes a lot of patience.To get a fit as good as this takes time and lots of tiny adjustments in the steps beforehand.

And a short video showing the almost completed fuselage.

So with the fuselage almost finished I turned to the wings.

Keeping with the theme of a higher finish I opted to try something a little different,hidden control linkages and obviously flaps.I had an idea for the alerons but wasn't sure how it would turn out so I decided to wait and see. 

One wing half with several amendments made to the plans,gotta love scratch building !!

4mm ply plate for attaching landing gear.

wing spars.

Wing formers and ply plate supports.

Cutting lose the aileron.

Balsa supports for hinges.

accetate hinges pinned thru balsa.

Control horn fitted.

Cutting lose the flaps.

Servo installation.

Ready to close up.

A couple of shots of the aluminium spar,it rests on the ply plate for the landing gear.

A short videon showing the wing functions.

At this point it's coming together quite nicely.There was an issue with joining the wing and I am hoping it wont come back and bite me in the behind when I try and maiden this.There is a possibility that one half of the wing was a little squint !!.Only a small possibility.

So covering,again I was wanting to try and make this model stand out so I tried a new covering material I haven't used before.I think it's came out ok......

Believe it or not but its covered in Fablon which is a self adhesive vinyl,the checker is good old tape.It's a first for me,never used it till now but I am sold.

This brings you up to date,there is a couple of things needing finished,landing gear for one,I need to source some heavier wire and buy some more wheels,possibly an Orange Flight Stabilizer RX and a windscreen,not that its needed but I feel it needs done.

Then it's the maiden......nervous to say the least so I shall wait for the best day I can get.

Plans are still in Sketchup SVG format.I am trying to learn Inkscape so as to produce plans in PDF format thats once they are finalised.

If you have read this all the way through I thank you and hope at the very least it may inspire you to try and push your build skills a little further.

Cheers

Scottie