Rudi’s Fokker E-III ‘Eindecker’ Build

Airdrome Aeroplanes - WW1 Replicas

Moderator: Moderators

User avatar
RudiGreyling
Too Tousand
Too Tousand
Posts: 2681
Joined: Thu Apr 28, 2005 7:41 am
Closest Airfield: The Coves
Location: The Coves, Hartbeespoort Dam
Has liked: 2 times
Been liked: 8 times

Re: Rudi’s Fokker E-III ‘Eindecker’ Build

Unread post by RudiGreyling » Mon Feb 05, 2018 3:06 pm

Build the Dream, Live the legend, Fly your Own Fighter!

Good Afternoon Av8tors,

I made some good progress on the engine mount and manage to fit the HKS Engine temporary to the airframe...more detail in the photos below:

I left you last time with the engine on a mock-up plywood firewall. So then I cut and fish mouthed lots of steel tubing and stick weld tacked it together, to make the engine mount fit around the engine especially around the horisontal cylinder extremities.
Image

This is what the engine mount looks like after I lifted the engine out of the way.
Image

Image

...and without the engine mounting platform.
Image

Then I took it to a certified airfcraft welder to TIG weld it together, I used Stefan at SA Kitplanes, that builds the Safari's.

Here the engine mount is back and trail fitted to the airframe
Image

Then I focused on finishing the floor, cut, measure and make to fit the airframe.
Image

Drill and clecko'ed the floor in place.
Image

Then a big milestone, hoist the HKS engine into position and tempory fit it, so that I plan all the engine accessories around it.
Image

another close-up
Image

view from the front
Image

The engine is actually very small, here is me for you to scale the installation.
Image

The plan is now to solve all the engine accessory placements like Oil Tank, Oil Cooler, Exhaust, CDI units etc etc.

Till next time,
Groete
Rudi
Amateur Kit Builder
WW1 Fokker E-III: viewtopic.php?f=324&t=190292
RV-7: viewtopic.php?f=64&t=3239
RV-10: viewtopic.php?f=64&t=48930
Goose1
Frequent AvComer
Posts: 633
Joined: Sun Sep 20, 2009 3:20 pm
Closest Airfield: FAWB
Location: Pretoria, FAWB
Has liked: 1 time
Been liked: 3 times

Re: Rudi’s Fokker E-III ‘Eindecker’ Build

Unread post by Goose1 » Mon Feb 05, 2018 9:55 pm

Mooi Rudi
At this pace you’ll start on the wings soon, then the fabric FUN starts. Have you decided on which fabric system you’re going to use?
Groete
Hans de Beer
AME A and H
PPL A and H
RV8 ZU-KEA
skin
Tripped over wheel chock
Posts: 29
Joined: Sat Mar 03, 2012 10:01 am
Has liked: 0
Been liked: 1 time

Re: Rudi’s Fokker E-III ‘Eindecker’ Build

Unread post by skin » Tue Feb 13, 2018 9:48 am

Well done Rudi. She looks beautiful allready...

Hendrik Loots
User avatar
Induna
1k poster
1k poster
Posts: 1127
Joined: Tue Mar 20, 2012 10:01 am
Closest Airfield: FASD
Location: Port Owen - Western Cape
Has liked: 12 times
Been liked: 9 times

Re: Rudi’s Fokker E-III ‘Eindecker’ Build

Unread post by Induna » Fri Mar 09, 2018 6:44 am

Nice! How is the build progressing?

I heard the HKS is a very economical engine...

Jacques
Jacques van der Westhuizen
ZU-xxx | VANS RV-8 in the making...
ZS-WSW | Sonerai 2L
User avatar
RudiGreyling
Too Tousand
Too Tousand
Posts: 2681
Joined: Thu Apr 28, 2005 7:41 am
Closest Airfield: The Coves
Location: The Coves, Hartbeespoort Dam
Has liked: 2 times
Been liked: 8 times

Re: Rudi’s Fokker E-III ‘Eindecker’ Build

Unread post by RudiGreyling » Mon Mar 12, 2018 11:32 am

Induna wrote:Nice! How is the build progressing?

I heard the HKS is a very economical engine...

Jacques
Hi Jacques, yes the HKS (4-stroke) is very economical compared to 2-strokes of same horsepower, +/- 9 to 10 liters per hour in the cruise.

Regarding the build...I have stagnated the last month contemplating what to do about the fuel tank. As a previous Vans Aircraft builder we are spoilt, cause everything is thought out for you and also everything is supplied, which makes things easy. I can now see why plans build, and manufacturing build projects stagnate and sometimes if it happens to often people eventually give up.

Any case, I did not get a tank cause it was to expensive to ship, the kit manufacturer sells a std 3mm welded aluminum tank that fits all his kits, so it is not custom to the airframe. I thought I could get it done locally. I got buggered around by 2 suppliers and they are also not willing to make it out of 2mm to save a bit of weight. This all costs time and was frustrating...

So I decided to build my own out of 0.032 (0.8mm) Alu Sheet, similar to how Vans Aircraft build tanks, it will save a ton of weight compared to 3mm welded. That meant I had to design and draw it. Below is basically what I came up with, a lot of detail is omitted that I will discuss later...It is basically a box tank with a sloped floor and a small sump for water drain and fuel reservoir. No baffles required since it is tiny and only holds 30liters, and is supported and bolted on 4 sides into the fuselage with slotted slip brackets.

Basic Dimensions (Not comprehensive) This is actually for a welded design I give the suppliers that buggered me around, but my sheet metal version looks closely similar.
Image

Basic fitment into airframe (Not comprehensive)
Image

First I cut the aluminum into shape. This is the tank Top, Front, Bottom and Rear all in one piece, that will be bent into the box shape. The small piece is for the bottom tank floor reinforcement. The Sheet is still covered with clear plastic, for protection, in all the photos.
Image

Mark and drill the reinforcement strips.
Image

Bend them on my small bender. This bender is handy for small bends, but the large bends for the tank I will have to get done somewhere this coming week.
Image

Tank floor reinforcement stips done:
Image

They fit like so, I also drilled all the rivet holes so long all along the main tank skin, where i am going to close the sides with a rib on each side.
Image

Then I drilled holes for the sump, filler and inspection/access hole:
Image

Drill the flanges for the sump and filler. I used an old wheel cover for the inspection/access hole cover.
Image

Clean everything up, plastic still on, ready to bend it into a box shape this week.
Image

I hope to bend it this week, at a sheet metal shop and then to start to construct two side ribs to close the tank.

Till Next time
Groete
Rudi
Last edited by RudiGreyling on Mon Mar 12, 2018 2:05 pm, edited 1 time in total.
Amateur Kit Builder
WW1 Fokker E-III: viewtopic.php?f=324&t=190292
RV-7: viewtopic.php?f=64&t=3239
RV-10: viewtopic.php?f=64&t=48930
Jel
Frequent AvComer
Posts: 613
Joined: Wed Nov 29, 2017 4:16 pm
Closest Airfield: FALA
Has liked: 0
Been liked: 0

Re: Rudi’s Fokker E-III ‘Eindecker’ Build

Unread post by Jel » Mon Mar 12, 2018 12:41 pm

Does it make me a bad person that I am happy to watch you build this rather than buy it? A lot more fun and more interesting... looking fantastic :!:
User avatar
RudiGreyling
Too Tousand
Too Tousand
Posts: 2681
Joined: Thu Apr 28, 2005 7:41 am
Closest Airfield: The Coves
Location: The Coves, Hartbeespoort Dam
Has liked: 2 times
Been liked: 8 times

Re: Rudi’s Fokker E-III ‘Eindecker’ Build

Unread post by RudiGreyling » Mon Mar 12, 2018 2:07 pm

Jel wrote:Does it make me a bad person that I am happy to watch you build this rather than buy it? A lot more fun and more interesting... looking fantastic :!:
Ha Ha not at all, the trials and tribulations of a home builder. Now you know why homebuilders love their airplanes so much, they have vested blood sweat and tears in them. :twisted:
Amateur Kit Builder
WW1 Fokker E-III: viewtopic.php?f=324&t=190292
RV-7: viewtopic.php?f=64&t=3239
RV-10: viewtopic.php?f=64&t=48930
User avatar
PJL
Six Tousand
Six Tousand
Posts: 6538
Joined: Fri Nov 10, 2006 12:04 pm
Closest Airfield: Pyramid Air Park
Location: Pyramid Air Park-Barberton
Has liked: 19 times
Been liked: 22 times

Re: Rudi’s Fokker E-III ‘Eindecker’ Build

Unread post by PJL » Mon Mar 12, 2018 3:31 pm

RudiGreyling wrote:
Jel wrote:Does it make me a bad person that I am happy to watch you build this rather than buy it? A lot more fun and more interesting... looking fantastic :!:
Ha Ha not at all, the trials and tribulations of a home builder. Now you know why homebuilders love their airplanes so much, they have vested blood sweat and tears in them. :twisted:
Indeed Rudi!!

PJL
To invent an airplane is nothing. To build one is something. To fly it is everything. — Otto Lilienthal

"When once you have tasted flight,
you will forever walk the earth
with your eyes turned skywards."
― Leonardo da Vinci
User avatar
ColdFingers
1k poster
1k poster
Posts: 1069
Joined: Sat Sep 17, 2005 9:22 pm
Closest Airfield: FADU Walkersons
Location: Dullstroom countryside.
Has liked: 3 times
Been liked: 0

Re: Rudi’s Fokker E-III ‘Eindecker’ Build

Unread post by ColdFingers » Mon Mar 12, 2018 9:01 pm

Rudi,

There are seven words that stand out for me in your last post...

"So I decided to build my own...".

Respect, sir.
Andy Mills
I'm supposed to respect my elders, but its getting harder and harder for me to find one now.
User avatar
RudiGreyling
Too Tousand
Too Tousand
Posts: 2681
Joined: Thu Apr 28, 2005 7:41 am
Closest Airfield: The Coves
Location: The Coves, Hartbeespoort Dam
Has liked: 2 times
Been liked: 8 times

Re: Rudi’s Fokker E-III ‘Eindecker’ Build

Unread post by RudiGreyling » Tue Mar 20, 2018 3:52 pm

Build the Dream, Live the legend, Fly your Own Fighter!

Good Afternoon Av8tors,

I love the smell of tank proseal, how I have missed thee! NOT !

So the tank is back from the bender and I made some progress.
Image

First make some wooden ribs to close out the tank sides
Image

Image

Perfect fit, less 1mm all around for metal thickness, round the edges.
Image

Then cut the rib out of sheet aluminum
Image

Sandwich the rib and get your plastic hammer.
Image

Bliksem the hell out of it, softly and gracefully bending the flanges
Image

Rib ready, plastic still on
Image

Perfect Fit
Image

Repeat for the other side and drill all the rib rivet holes, make some brackets and trial fit the sump and figure out where to drill the outlet holes.
Image

Trial fit in in the aircraft...it fits
Image

Mix some Proseal...Yuck I hate this stuff
Image

Proseal the tank bottom stiffeners in place...wait to dry
Image

Put a rivet in the Rib tooling hole and proseal it too.
Image

This week is now a process of systematically sealing and riviting the tank closed...

It was interesting scratch building the tank, learned new skills, I take my hat of the scratch builders or plan builders...it is a lot of effort.

Till Next Time,
Groete
Rudi
Amateur Kit Builder
WW1 Fokker E-III: viewtopic.php?f=324&t=190292
RV-7: viewtopic.php?f=64&t=3239
RV-10: viewtopic.php?f=64&t=48930
User avatar
Peter Connan
Ooops forgot to turn the fuel back on!
Posts: 482
Joined: Mon Sep 08, 2014 7:29 pm
Closest Airfield: ORTambo
Location: Gauteng
Has liked: 236 times
Been liked: 36 times

Re: Rudi’s Fokker E-III ‘Eindecker’ Build

Unread post by Peter Connan » Wed Mar 21, 2018 6:55 pm

Rudi, where does one get Proseal?
Nikon D500. 500mm f4, 24-120mm f4, 105mm f4 micro, 55mm f2.8 micro, Tamron 15-30mm f2.8
User avatar
Theuns v V
10000 and still climbing
10000 and still climbing
Posts: 11699
Joined: Sat Sep 01, 2007 6:26 pm
Closest Airfield: Rand
Location: JHB
Has liked: 11 times
Been liked: 79 times

Re: Rudi’s Fokker E-III ‘Eindecker’ Build

Unread post by Theuns v V » Thu Mar 22, 2018 6:34 am

Peter Connan wrote:Rudi, where does one get Proseal?
I got some at Placo rand

T
User avatar
RudiGreyling
Too Tousand
Too Tousand
Posts: 2681
Joined: Thu Apr 28, 2005 7:41 am
Closest Airfield: The Coves
Location: The Coves, Hartbeespoort Dam
Has liked: 2 times
Been liked: 8 times

Re: Rudi’s Fokker E-III ‘Eindecker’ Build

Unread post by RudiGreyling » Thu Mar 22, 2018 7:03 pm

Peter Connan wrote:Rudi, where does one get Proseal?
Ussually Placo, but this batch was from NAC wonderboom...just less than R500 for the tin inc VAT
Amateur Kit Builder
WW1 Fokker E-III: viewtopic.php?f=324&t=190292
RV-7: viewtopic.php?f=64&t=3239
RV-10: viewtopic.php?f=64&t=48930
User avatar
Peter Connan
Ooops forgot to turn the fuel back on!
Posts: 482
Joined: Mon Sep 08, 2014 7:29 pm
Closest Airfield: ORTambo
Location: Gauteng
Has liked: 236 times
Been liked: 36 times

Re: Rudi’s Fokker E-III ‘Eindecker’ Build

Unread post by Peter Connan » Thu Mar 22, 2018 7:07 pm

Thanks Theuns
Nikon D500. 500mm f4, 24-120mm f4, 105mm f4 micro, 55mm f2.8 micro, Tamron 15-30mm f2.8
User avatar
Theuns v V
10000 and still climbing
10000 and still climbing
Posts: 11699
Joined: Sat Sep 01, 2007 6:26 pm
Closest Airfield: Rand
Location: JHB
Has liked: 11 times
Been liked: 79 times

Re: Rudi’s Fokker E-III ‘Eindecker’ Build

Unread post by Theuns v V » Fri Mar 23, 2018 8:49 am

Ask them for tins that are about to expire, they usually sell these a little cheaper.

Return to “Airdrome Aeroplanes”