Hangar 9 60cc Corsair Build

[camss69]

Only one soccer game today so I had some time to work on the Corsair. I bought the Keleo firewall kit for the Saito 84. You cut off the stock firewall, build the replacement firewall/box and it slides into the motor box. I got it all assembled today, it's clearanced so the Keleo exhaust ring fits and lets you mount the 84 without having to cut holes in the cowl. There's quite a few pieces to it, the firewall itself is 6 laminated pieces of 1/8" ply. After I got it all assembled I marked the existing firewall to be cut off, I'll try to get that done tomorrow.

 

[camss69]

I also couldn't resist putting on just a little bit of vinyl... I figured since the tail section was pretty much done I'd just do the stuff on the rudder to see how it looks. Way nicer than the included decals. I think it's going to look pretty good.

 

[camss69]

Got the firewall cut off today, came out nice and clean. A quick trip to Lowes to get the right tool for the job, I bought this metal cut-off wheel that specific for wood. Went through it like butter. I sanded the corners and sides of the new firewall box to get it to fit easier. Next I'll bolt the engine to it, put the cowl on and adjust and mark it to have the prop the proper distance from the prop to the cowl and then glue it in place with epoxy.

 

[Tom Schultz]

Looks like your modification to the firewall is coming along nice.
Just curious what did you think of the installation manual? Did I miss any steps when writing the manual?

 

[camss69]

Hi Tom, it seems pretty good, one difference I noticed was the middle two layers of the firewall (the ones with the tabs) on mine were slotted on one side? Not sure why. Also the side of the firewall box with the offset or the pilots left side of was marked with a hole in it? I'm assuming to show its the left side? The parts pictured in the manual didn't have those differences.

I noticed you used what looks like about a 1/8" or 1/4" standoff? Was that necessary for the exhaust ring to clear? If not could you have just slid the firewall further forward and eliminated the stand off's?

I was surprised how easy it was to cut the firewall off and get a nice clean cut, helps to have the right tools for the job.

The laser cut parts smell like BBQ.

 

[Tom Schultz]

I noticed in your pictures the two layers were slotted and the left side of the box shows a hole. I'm thinking Kelvin added that so the hole will line up with the choke on the carburetor.

On my cowling (pilots left side) I have two holes, front one is for the choke/slow needle and other one is for the main needle.

The four standoff came with the Satio engine. Part number 95-2 in the manual. The standoff's allow air to get behind the engines back plate and into the carburetor.

www.horizonhobby.com/pdf/SAIEG84R3D-Manual.pdf

Also thanks for the advice on the vinyl graphics.

Tom

 

[camss69]

I was wondering if that's what the holes were for, that makes sense now.

I'll use the standoffs also then, lol.

No prob on the vinyl, post some pics if you've got them!

 

[Tom Schultz]

Here are some pictures.

 

[Tom Schultz]

Some more pictures.
I also made a box to store the plane in so it doesn't get damaged in the garage.

Tom

 

[camss69]

Nice! Plane looks great and I like the box idea.