Brand New Goodness!

We are now officially into SDLAN V8.0!

We are pleased to unveil the new SDLAN website. This was a major facelift that has been going for the last little while. There is a bunch of new tech under the hood here that will hopefully make the website feel faster after the initial load…. of course it may prove to be a disaster, but thats the fun of website experimentation!

There is a chance that the interaction will be a bit frustrating, we are working on fixing that issue (the issue of switching between tabs and using the back button).

Enjoy!

Major Garage Updates!

Several new posts in the Garage Build!

Topics included electric, foundation, walls and roof :)

 

Quick and effective jig to get the really heavy 5/8 boards to the roof/

Quick and effective jig to get the really heavy 5/8 boards to the roof/

Finishing off the gable end ladders.

Finishing off the gable end ladders.

New meter base wired and ready for cover

New meter base wired and ready for cover

Still alive!

Well we are still alive… mostly. More major house renovations and assorted other commitments (web developing and such) have precluded much updating.

A point of interest, it is quite an undertaking to install a bathroom in a basement of a house. Its even more so if that house is on a septic system and you have to install a sanitary pit!

Sump pit installed! Final gravel going in.

Sump pit installed! Final gravel going in.

Digging the hole to China!

Digging the hole to China!

Rifted!

The Oculus rift has arrived! Actually it arrived several weeks ago. The unboxing images will be up shortly.

Suffice it to say, it has been a life changing event! So far only Portal 2 has been tested out on the unit on the gaming front and it was amazing. Currently the push is to test CAD model viewing and walk throughs using the Unity engine and the Oculus Rift.

The Oculus Rift – in time

The headset for the APP-02 platform has officially been purchased! After reading through many reviews, technical descriptions and pricing evaluations the Oculus Rift system came out as the clear leader.

The waiting game is now in full swing. At this time the dev kit is all that is available for this system and it apparently is now shipping some time in December.

As it stands right now the App-02 has not flown in a while and is still awaiting the installation of the Eagle Tree system so the delay in delivery of the Oculus Rift is not a show stopper.

With the Shed-04 (Garage) project winding down work will hopefully be commencing again on APP-02… along with some more flights hopefully!

Oculus Rift'ed

Oculus Rift’ed

The Eagle Has Landed!

The latest update to the APP-02 platform has arrived! Several new sensors are ready to be installed (altimeter, GPS, engine temp, etc.) along with a complete data logging system.

Also included in this a a new 3-axis electronic stabilization system. It operates on complete solid state electronic gyros (or accelerometers if you prefer) and promises to make the plane fly like it was on rails! As an added feature it will also protect the several thousand dollars of equipment onboard now!

The next step is to finish repairs on the tail wheel (it was “removed” in a particularly rough landing on its last flight) and add in the new equipment along with the SLR camera!

After this the plan is to find someone crazy enough to rent out a FLIR camera :)

The complete kit!

The complete kit!

Shed-04 Updates

So we have updated the Shed-04 page with some new pictures and moat digging pointers!

Here is a teaser picture, check out the Shed-04 page for further information:

A simply massive amount of dirt!

A simply massive amount of dirt!

Silence of the deathly!

So first up… its been a long time since anything was posted here. This is sad :(

On the plus side the reason is that much progress was being made on the “Shed”! More complete information and pictures will be posted in the near to distant future depending on time. Suffice it to say this project is huge! It turns out its a very big deal to build a complete two car garage with no experience and just a husband and wife team…

In a brief description the foundation is complete, the walls are up, the roof is on and the electrical work is started.

So more information will come down the line… hopefully soon!

The Garage Attack

The garage project (a.k.a. Shed-04) has begun! Siding is down, just waiting to get the foundation going!

Garage Side!

Garage Side!

90% complete wing

The wing model of the Bearhawk is some 90% complete! Next up is working on the fuselage and learning the weldaments features in Solidworks.

90% completed wing!!!

90% completed wing!!!

 

Bearhawk Modeling Online!

The modeling of the Bearhawk airplane project is back online! A section has been created under the Bearhawk project menu to track all the modeling progress on this project.

Click here for a direct link to the page.

Wing with mostly complete Aileron

Wing with mostly complete Aileron

Flap Drive Mechanics

Flap Drive Mechanics

New (old) Project and some minor updates
The Bearhawk!

The Bearhawk!

The Bearhawk project is back! After a long time off line (due to the loss of the previous website), the Bearhawk airplane project is getting back online! More information is available under the new Beahawk menu.

On another note, icons have been added to the menu! Now I just need to get some that dont look quite so ugly.

Flight F-002

So the APP-02 had its second flight! You can read more about it on the APP-02 page here.

First Run!

The first run of the APP-02 airplane went down last night! It was a resounding success. The DA-50 single cylinder engine vibrates fairly aggressively at low RPMs. This issue will likely have to be addressed after reviewing the first flight video to see how the vibration works out in the air.

The issue with the vibration may be a ground related issue and might be dampened when in flight. If not the gimbal will be re-mounted on a foam shock pad.

The video of the first run will be uploaded once it has been edited and compressed.

Video Foray

Minor update, put together a little video snippet for youtube about the GoPro gimbal mount in the APP-02 airplane.

Gimbal’ed

The Gimbal mount is completed! The camera just hast to be fully mounted in it once the gimbal is finally mounted in the frame. It turns out that it was a good thing to get such a beast of a plane… all this camera equipment is going to take up a large amount of space, especially when the SLR is finally mounted in there.

Check out the mount page for all the information.

Gimbal mount & GoPro mounted

Gimbal mount & GoPro mounted

New Uber Menu

So the news today is a seemingly minor update to the website that took quite a bit of work to implement. The fancy new menu system! Ta da!

The new menu system is powered by jQuery UI, quite possibly the most flexible and easy to use user interface (UI) development framework out there! It took a couple of days of trying to do it with a custom solution before realizing the ease and power of jQuery UI. The new system even remembers what menu entries were open when navigating pages :)  No cookies were used or harmed in the making of this menu.

The graphics have also been updated slightly to look a little nicer. At some point some nice context appropriate icons will be put in there too (maybe).

As for the other projects, the APP-02 platform is getting really close to its first flight. The only thing remaining is to install the switches when they arrive, and the GoPro mount. There will be a new projects page opened up soon for the GoPro mount that is being built for the APP-02.

Enjoy!

Latest and greatest!

So WordPress is basically the best. Just updated the site to the latest version of WordPress and it was actually completely painless. The site was down for maybe 30 seconds. Hopefully it stays painless. Time to experiment with the new media manager!

APP-02 Info Top-up

Finally some new pictures of the APP-02 progress! Its almost there. More information is available on the project page.

Image of the covered plane! Finally!

Build Permit

The build permit for the garage has been applied for! It should be in the mail soon, construction will begin around June.

The full drawing package will be uploaded shortly.

New APP-02 Work!

New photos have been uploaded of the APP-02!

 

The plane is on its gear and being covered!

Project BearClaw

Project BearClaw is being revived after several months of down time. Things got very hectic and busy with the garage design and other renovations that the BearClaw project was back burnered.

For some background this project involves the construction of a four (4) place Bearhawk airplane. Work has begun by converting the 2d paper drawings into a 3D CAD model that will allow for better visualization of the construction and assembly. So far this method has allowed for a few glitches to be sorted out before assembly has begun. There are also several modifications that will be done to the design using the model.

For now here is a screen shot of the wing in its future construction hanger!

Bearhawk wing in garage, being used to layout work areas in the garage design.

Reno’s Show

We attended the Ottawa Home Renovations show this past Saturday. Quite a bit of interesting stuff. Pricing was procured from three manufactures of garage doors for our new garage project. Sadly like most other things they are substantially cheaper in the U.S.A.!

One very interesting display was from a local ICF rep. We will be putting together a bill of materials for them to quote on. One other thing we found is that excavators are very expensive to rent (around $195/day)!

Things are ramping up on this garage project and hopefully the drawings will be in for the building permit in a month or so.

More information has been posted in the shed-04 project page.

Finished walls with electrical and incorrectly sized garage doors.

APP-02 Moving Along

More pictures of the APP-02 project will be coming soon. Work has been progressing quite well on it. All the servos have been ordered (2 are in, waiting on 3 more) and the air frame is basically structurally complete.

The focus now is on the cowling and all the hundreds of little details that go into basically making a UAV.

Below is a picture of the fueling/electrical master switches that will be used and the opto-isolated ignition cutoff that will allow for remote shutdown of the engine.

Master ignition switch and receiver switch combined with fuel port.

Opto-Isolated ignition cut-off switch for motor to allow remote shutdown.

Welcome to 2013!

Happy New Year!!!

This is officially going to be declared the year of the garage. The holiday season was a bit of an up and downer this year, as we were hit hard by a flue bug. On the plus side this started myself well down the path of weight loss! On the negative side it was discovered that no one keeps reading material in their bathrooms anymore! Whats up with that? Yet another reason to push for a tablet.

On the tablet front, there are no good Android tablets out there at this time that match the Apple iPad 3. The Samsung Galaxy 2 is very close, but has absolutely no cellular data capabilities. If it had that it would edge out the iPad 3. Therefore the iPad 3 will continue to collect my drool, having no money to buy either device as the savings for the new garage and the Airborne Photography Platform are taking all available resources.

On that note, new renders for the garage!

New Garage Work

Minor update today, some new renders have been added to the garage page. Not to much just putting together the walls. This will be the final incarnation of the garage design!

Hopefully we will be applying for the build permit towards the end of March.

Shed – 04

A new page has been added under projects for the 4th iteration of the design of our future garage. Everything was in line with the 3rd iteration but some significant design changes were made that necessitated a significant modification of the design over the next few months.

Footings & first row of ICFs

Amvic 6″ Straight ICF Model

Project – Airborne Photography Platform – 02

New project! Started the projects page for the APP-02. This project is an experiment in taking aerial photography and first person flying.

Welcome

Welcome to the new SDLAN / BearClaw / bunch of other projects site!

After the disaster that befell the previous version of this website (the BearClaw site) this newly revised site has many nicer features, mostly for administering and uploading information to the site. The previous site was completely home built, this site uses a much nicer content management system (CMS).

As more information is progressively added I hope you will find some of this information useful, entertaining and possibly informative.

Brand New Goodness!

Taranis Arrivus
Shiny new tech!

Shiny new tech!

 

 

 

 

 

Shiny new radio has arrived! This is the future of the APP-02 project (and by extension) all future projects. So far it has been un-boxed and turned on, and it did really well at those two things :)

The waiting game is on now for the receiver so that it can be fully tested. In the mean time hacking is commencing with the end goal of allowing the Oculus head tracking to be transmitted to the receiver.

F-002 (Flight-2) – Fly – Deadstick – Crash —- Sadness

So  the second flight (F-002) of the APP-02 platform has been completed. The airplane has LOTS of power with the DA-50. The new soft-mount for the Gimbal system seams to have taken a substantial amount of the vibration out. Essentially the Gimbal base servo is now mounted on silicon tubing buffers that dampen out the vibrations.

The flight went basically well until about 2-1/2 minutes in when the fuel pickup line in the fuel tank vibrated off and the engine starved of fuel. At this point the plane was flying away and over a less than optimal portion of the field at a relatively low altitude. A right turn was attempted but the maximum bank angle of the week was exceeded and the airplane lost a substantial amount of altitude. At this point it was decided to level out and bail into the field. This area of the field was full of water and the soft ground sucked the landing gear in and tore it from the airframe.

All in all it could have been much worse only about 40$ worth of damage was done but there will be some upgrades made before the next flight. These upgrades include a new servo tray for the gimbal system, bigger wheels and a beefed up landing gear mount to support the weight of the plane.

Here is the video!

 

First Flight!

The first flight of the APP-02 platform took place this past Sunday! After a mostly successful lift off the plane was trimmed and flew fairly well. The plane files very differently from anything else I have flown before. Its big and heavy!

After doing several laps around the field it was decided that practicing some landing approaches would be in good order.  Unfortunately after lining up with the landing strip,  the plane got to slow in the air and stalled. It fell about 10 – 15 ft to the “runway”.  Thankfully no serious damage resulted, just a bent landing gear strut and broken propeller. A new prop is on order and the landing gear has been fixed up.

An edited video of the adventure (up to and including the “landing”) is available here:

 

Almost there!

So its getting closer to a flyable state! So close, 90% complete 90% to go. Picked up some hatch screws today… turns out I lost my yellow handled square end screwdriver for them. The details are killers.

This week the paint for the paint for the cowling should be procured along with the last of the control horns and a yellow handle screw driver to finish off the servo hatches on the wings. The air speed sensor is also installed and hooked up. It was tested by blowing over the pitot tube (not directly into it). So far it seems to work well, looking forward to getting the full telemetry system on line. One nice advantage of a plane this big is the huge amount of room to put stuff!

The fuel/switch combo and engine ignition isolation switch have also been ordered. Looking forward to getting these installed along with the throttle servo as these are the last couple of keys holding up first flight.

Here are some more pictures:

Image of the covered plane! Finally!

Zoomed out image of the wing with sensor tubing and wiring
Wing before covering, shown here is the servo and airspeed sensor.
APP-02 Progress

Progress has been moving along on the APP-02 project. The airplane is now in the covering stage and will hopefully be ready for first test flight some time in late March. So far the servos have been fitted out and the structure is complete. The radio system has been laid out and is waiting installation.

Below are some pictures of the current build:

The plane is on its gear and being covered!

More fiber glass work… fine sawdust was used to make a filler paste

Cowling Fiberglass work (I hate doing this)!

Progress to date

Description:

Welcome to the APP-02 page. The goal of this project is to create a platform from which airborne photography can be explored. Ideally this vehicle will be as inexpensive as possible while still being as flexible as required for several different roles.

Great Planes Super Decathlon

After much research the Super Decathlon kit from Great Planes was selected. This kit is designed for either nitro or gas power up to 35cc. To power this aircraft the Desert Aircraft DA-50 has been selected. Sure its overkill at 50cc but it should really get the airplane moving and there is going to be a substantial amount of weight in the plane when it is all up.

The DA-50 was chosen due to the large number of reviews attesting to its performance and its tremendous power to weight ratio. This engine is essentially CNC carved from a billet of aluminum so any extra material is removed from the casings. The engine is a 2 stroke gasoline engine increasing the power output and reducing the weight significantly. The tradeoff is in fuel economy, however this is a somewhat debatable figure as the power output is high enough that it is unlikely to be run at full power very often.

Electronically the APP-02 platform will be flown using a Futaba 9CAP radio system with Futaba receiver and servos. This airplane requires a minimum of 6 servos running on 4 channels if the servos are combined together using Y-cables. There are some unique requirements for this particular model however that will require further channels. This model is going to have a GoPro Hero 2 camera mounted on a dual axis gimbal system allowing for pan and tilt while flying.

Electronics:

Electronics Flow Diagram

As mentioned above the APP-02 will be using Futaba equipment for control. On top of this it will have a GoPro Hero 2 camera for picking up a live “first person” view of the the flight. The live video feed is going to be transmitted to the ground via an Eagle Tree telemetry system. This signal will be fed into ideally a set of Vuzix 920 video display glasses with the head tracker add on. The goal will be to hack this head tracker to work with an Arduino controller that will super-impose two channels onto the 9CAP transmitter signal controlling the GoPro gimbal mount servos. This will likely be a pain…

After all this is up and running the goal is to side mount a Digital SLR camera that will take high resolution stills.

Progress to Date:

To date the airframe has been about 75% completed. Work is being done on the fuselage right now which is requiring substantial modification to fit the 50cc DA-50.

Airframe Together With Motor out Front

Vertical & Horizontal Stabilizers

Completed Wings Waiting for Servos

Partially Complete Fuselage

Video Mode

A quick video of the gimbal mount installed in the airplane posted on youtube!

Gimbal Mount’iness

So the gimbal mount is basically done! This has to have been one of the easiest parts of this whole project. PVC was the correct material to build this out of, it was easy to work with and handles machining quite well (saws and such). The whole assembly is actually held together by #2 screws with an aggressive thread and PVC glue (the regular plumbing type).

The mount was tested and has now been installed in the airframe. A video of it working will be made and uploaded soon.

The initial design called for a restraining bracket to be fabricated to hold the GoPro in the mount but simpler tie-wraps will likely be used as they are effective and easier to install.

Here are the pictures!

Gimbal mount & GoPro mounted

Gimbal mount & GoPro mounted

GoPro in mount in fuselage.

GoPro in mount in fuselage.

Gimbal constructed side view

Gimbal constructed side view

Front view of Gimbal

Front view of Gimbal

Underside view showing servo mount

Underside view showing servo mount

Rear view

Rear view

Gimbal camera table

Gimbal camera table

GoPro Gimbal Mount

The purpose of this project is to build a 2-axis gimbal mount for a GoPro camera to be used in the APP-02 project. The goal of this project is to create a gimbal mount that will allow a GoPro camera to pan and tilt.

Standard radio control servos are used to provide the actuation of the mount. PVC plastic is being used to provide an easily machined structural material for the mount that can withstand the vibration and stresses of flight. The initial design called for ABS plastic, but PVC was more readily available.

Here are some images of the model:

Gimbal with GoPro Camera

Gimbal with GoPro Camera

Side View of Gimbal Mount

Side View of Gimbal Mount

Exploded View of Gimbal Mount

Exploded View of Gimbal Mount

Servicing of the Change

Perhaps the biggest challenge in this project was the relocation of the main service to the house. Unfortunately the garage had to be built on the electrical service entry side of the house. This necessitated a re-location of the main electrical power for the entire site from the house wall to the new outside wall of the garage.

The single piece of advice here is “hire an electrician”!! Or if you enjoy stress and the unknown proceed on your own. On the project the latter option was chosen.

The new service panel was installed in the garage along with the new utility meter base. The wiring to the house was pre-pulled and ready to go on the day of the change over. They utility company arrived early in the morning and rather than removing the wires from the house simply cut the wires with bolt cutters. This essentially commuted us to plan A as it eliminated any chance of re-connecting the house using the old service.

Shortly after the utility company cut the house off the local electrical inspector arrived to see how the day was going to go. He immediately informed us that he would not approve the main cable that we had pre-installed as it did not meet his requirements for installation in a wet area (even though it was in a sealed conduit… and the individual wires had a wet rating… just not the outer cover). We were informed that we would have to remove this main cable, source and then install the correct cable to his specification all before he would authorize a re-connection of the house to the utility. Thankfully the correct wire was readily available and it did not take long to remove the original cable and install the new. Once the new cable was installed and terminated at both existing  house panel and the new garage panel (with a 100A breaker) we were ready for the inspector to come again.

The formal inspection that afternoon went quite well and no issues were raised. The utility company then arrived to reconnect the house, however they were concerned that the sand used to back-fill the buried side of the utility service did not meet their specifications. They would only re-connect the house if the correct sand was ordered immediately. This was done and 60$ and a front end loader full of special “magic electrical” sand later they re-connected the house.

All in all a very stressful day running on a borrowed generator to keep the fridge and sump pump going. In the end though everything worked and has since been functioning without issue.

New panel for the garage.

New panel for the garage.

New meter base wired and ready for cover

New meter base wired and ready for cover

Service panel mounted... Wrong cable shown here!

Service panel mounted… Wrong cable shown here!

Walls and Trusses

Unfortunately we skipped taking pictures of the walls going up. Suffice it to say, it was quite a bit of work. Thanks must go out to our neighbor for letting us use his exceptionally flat yard to build the walls on.

The walls are constructed of 2×6 by 12ft length lumber and sided with 7/16 asponite. Framing nailers make everything much easier when building! It took the better part of a day to build the walls and about a week to sheet everything with the asponite. Keep in mind when building walls, the walls will be extremely flimsy until the roofing structure is complete! It is essentially to carefully brace the walls so that they are structurally sound and can take any wind loads while being constructed.

After the walls were up and sheeted, the trusses were placed on top. This was very much a team effort! Pr-engineered trusses were used on this project as it made obtaining the build permit much easier and the cost of the per-engineered and manufactured trusses was actually cheaper than self building them!

The trusses were delivered to the driveway and a team was organized to help get them up and into place. As can be seen in the pictures below several poles were used to assist in getting the large trusses up. Also note the temporary cross bracing between the trusses, this is essential to ensure that everything stays together through out the assembly.

One critical note is ensure that the wall dimensions front to back stay the same! Especially around the middle of the wall. The walls will tend to bow as the trusses are placed and unless careful measurements are made and re-made during the lift this bow will be permanent… and its a pain.

Finishing off the gable end ladders.

Finishing off the gable end ladders.

Spacing the trusses.

Spacing the trusses.

First trusses being loaded up.

First trusses being loaded up.

Organizing part of the crew.

Organizing part of the crew.

Quick and effective jig to get the really heavy 5/8 boards to the roof/

Quick and effective jig to get the really heavy 5/8 boards to the roof/

Foundation Up-goer

The foundation going up!

On this project we used Insulated Concrete Forms (ICF) as they were the most cost effective foundation system. ICFs are typically considered a premium product, however as we were self performing the entirety of the foundation work they eliminated a lot of wast material.

A cost analysis was done early on in the design stage for the garage to establish the preferred foundation system. Several civil contractors were contacted that specialized in foundations for quotes and they came in between $10,000 and $12,000 CAD! These quotes did not include the cost of the concrete or rebar re-enforcement either! After exploring the subcontracting route, self building the forms was explored. There was in initial idea to try to re-use the formwork materials elsewhere in structure, however the wood used would be heavily damaged by the concrete curing process and no longer suitable for use in the structure. The materials used to build formwork would be quite costly and as it would be completely waste material afterwords this would be a large sum of money to simply dispose of.

After taking a close look at the various costs ICF came out as the clear leader in cost advantage. On the plus side it also makes for an extremely thermally sound foundation that will have minimal heat losses. ICFs are also extremely easy to assemble and go together really fast. It took only 3 days to go from an empty trench to a concrete filled ICF foundation wall!

If you are looking for advice on ICF construction and an excellent price, contact the EMM Group (Phone #613-835-2600). EMM Group supplied a complete package including the concrete and rebar.

 

Bracing the ICFs to hold the concrete.

Bracing the ICFs to hold the concrete.

Final prep for concrete!

Final prep for concrete!

Just waiting for the concrete to arrive.

Just waiting for the concrete to arrive.

All the wall anchors in place and concrete left to cure.

All the wall anchors in place and concrete left to cure.

A fraction of an hour later and its done!

A fraction of an hour later and its done!

Fill The Moat!!!

The foundation is going in! This turned out to be the first of the many  “interesting” adventures on this project. As it turns out having absolutely NO trade experience and a disregard for any sense of detail.

As it turns out hours spent ensuring complete squareness and alignment of a footing are NOT hours wasted. To put things in perspective it is absolutely essential that the footing be square and aligned to the structure if you would like a square final product… these errors DO NOT cancel out, instead they compound and make life very very difficult later on.

The footings are going in here and as can already be seen the trench was not dug square, thankfully it was dug wide enough to accommodate this error. When laying out the formwork for a footing plan on spending at least 2 to 3 hours laying out string lines. This is about the minimum amount of time to get it right. If you have gone faster than this you have done it wrong… guaranteed.

Also note the power line running into the house… this proved to be a real treat to work around during the majority of the heavy work on this project.

Footing for the front wall.

Footing for the front wall.

Back wall footing, note the step down due to the high ranch house.

Back wall footing, note the step down due to the high ranch house.

Long side wall. We were just below the water table here due to all the rain.

Long side wall. We were just below the water table here due to all the rain.

Footinglishous...

Footinglishous…

The big’ish dig!

So the big dig in Morewood commenced (on May 5, 2013). After taking down the siding on the end of the house the next step was to begin the digging for the new garage foundation. This turned out to be a fairly big task!

We rented a mini-excavator from United Rentals. To be honest this mini-ex was barely up to the task of digging this foundation. It took approximately four (4) days of work with the mini-excavator to get the land pulled back and the foundation trench done.

There are a couple of tips here for anyone looking to do this sort of thing:

  1. Rent a bigger excavator! Bigger is better, or hire some one to do it.
  2. Make sure you have some one in to do your locates before you dig! We knew the power to the house was buried where we were going to be digging, however we still had the locates done. This was a good thing as we were surprised to see where the cable was actually routed underground! Instead of running right to the pole it went around the driveway.
  3. There is a LOT of dirt underground!
  4. Have a friend around to help, one person on the excavator and one person in the trench to keep track of everything and level the trench bottom.
  5. Layout, layout, layout… the key to a straight parallel trench is to layout your dig lines.

And here are some pictures!

5ft deep moat

5ft deep moat

The finished trench!

The finished trench!

A simply massive amount of dirt!

A simply massive amount of dirt!

The fore(wo)man at work?

The fore(wo)man at work?

The first part of the dig!

The first part of the dig!

The "hired" help... thanks dad!

The “hired” help… thanks dad!

 

Prepping Prepping Prepping

Work on the garage has truly begun! We have started by removing the siding on the house where the garage will be built. This was somewhat melancholy as we actually put this siding on last year.

The plan is to dig the foundation and footings wall this weekend with the ICF (Insulated Concrete Forms) materials being installed and filled with concrete in the following week.

The footings as per the plans are 12″ x 24″ and are being framed with simple 2″x12″ boards supported with 2″x4″s. The hope is to preserve this wood for later use in the structure of the garage.

Here are some pictures of the project beginning:

Garage Side!

Garage Side!

Siding removed

Siding removed

The hydro entrance to the house will be relocated

The hydro entrance to the house will be relocated

The Garage Begins!!!

The garage project (a.k.a. Shed-04) has begun!

So far the siding has been removed from the outside wall of the house that will be shared with the garage. It looks like operation loose weight while climbing scaffolding has commenced. The siding has all be removed, now the corner trim pieces have to come off and a little more siding will have to be removed and re-jigged a bit when we go to side the new garage.

The complete set of garage drawings are available now… free to download! Of course this comes with the typical litigious statements:

  1. No warranty is implied or given
  2. If you kill, maim, injure, disfigure yourself or otherwise suck at building this garage you do so at your own risk
  3. These drawings are in NO way confirmed to be structurally sound and have NOT been stamped or reviewed by an engineer

All that being said, if you want some ideas on where to begin, or want to review what is being done feel free to download these drawings:

Shed-04 Complete Drawing Package!

Shed-04 Complete Drawing Package!

Electrification’ism

The 4th revision of the garage design is coming along quite nicely. Having now done this 4 times helps a lot in!

Some of the significant changes are a removal of the windows in the outside wall. After analyzing other workshop garages it was found that these windows serve little purpose other then to collect large amounts of dust and debris that never gets cleaned up. The garage doors have also moved from a 10’x10′ door size to a 10’x8′. These renders actually have the wrong door size completely in them (something silly like 10’x 7.5′)  due to a miss-calculation. This has now been fixed in the design but no new render has been made yet.

The 10’x10′ door size was found to look to imposing and “commercial” beside the house. Also the 10’x10′ doors have proven to be quite expensive and likely would have been too close to the ceiling height to allow for a standard chain drive opener.

The garage doors will be purchased from the U.S.A. as they are roughly half the price for the same specifications as doors available in Canada! The only downside to this is they will have to be self installed. Just one more thing to learn how to do…

Garage interior view. Yes the floor will be polished!

Finished walls with electrical and incorrectly sized garage doors.

Up Go The Walls

Quite a bit has been accomplished now on the garage rev four project. The foundation is complete and the pad is done, now the walls are being designed.

This garage is going to have a standard 2×6 16″ center stud wall construction and will be insulated with R22 Roxul insulation (best stuff on the planet outside of full ICF construction). As you can see in the middle render initially the electrical panel was going to be incorrectly positioned as counter sunk into the wall. This mistake was actually present in all previous design iterations and was only caught today. Essentially countersinking the panel would mean no insulation in this area and a significant heat loss. The panel will now be surface mounted on a back board and probably closed in with a nice looking wooden cabinet at some point.

As with the previous garage iteration, the electrical panel in the garage will be 200Amp rated and will back-feed the house panel as the service entrance to the home is being relocated to the outside wall of the garage.

A files page will soon be coming that will have the complete model of the garage available for download for people who would like to use this design for ideas or replication.

Wall Studs

Outside wall sheeting and improperly laid out electrical panel.

Side view of garage looking from house, surface mounted electrical panel, using model man to layout electrical fixtures.

 

Footings complete

The footings are completed, well design wise anyway. As you can see in the attached render the footings have been laid out, all the rebar is designed into the model so it should be a fairly trivial thing to generate a fairly complete bill of materials.

 

Garage wall framing going up.

Foundation wall ICF construction

Foundation’ing

Welcome to the new garage design. This is the 4th iteration of the garage design for our house. The previous designs suffered from location issues (original location taken over by septic system) design flaws and general construction issues.

This fourth design will be incorporating most significantly the use of Insulated Concrete Forms (ICFs) for the foundation. The other significant change is the removal of the 4th wall that was going to be built over the current exterior wall of the house. This was really just a significant amount of over engineering and served no significant purpose (other then to take up space).

As you can see from the images below, the garage foundation has been largely modeled, it did not take as long as anticipated to do this (about 2 evenings to generate the parts). For some reason the SolidWorks rendering engine really does not like this model!

Brand New Goodness!

Bearhawk Airplane Build
Not quite what ours will look like, but the future!

Not quite what ours will look like, but the future!

Welcome to the Bearhawk Airplane Build project. The goal of this project is to build the 4-place Bearhawk airplane designed by Bob Barrows.

After many hours spent researching different designs we have settled on this particular one as the best fit for our needs. All aircraft projects are truly an exercise in compromise. Our criteria for this plane was:

  1. Four seat capability minimum for family traveling
  2. Simple & safe
  3. Good back country capabilities
  4. Float capable
  5. Low cost (probably the most important)

Based on this criteria we settled on the Bearhawk design.  The advantages of the design are the Aluminum wings with the simple and solidly designed tubular fuselage. The fabric covering on the fuselage was initially a detractor but after some research it was considered an asset as it is much simpler to create a tubular frame that is lightweight and structurally sound without using advanced computer simulation.

The first steps in our build have been to fully 3D model the construction process of this aircraft. Starting with the wings we have been modeling the aircraft and will be incorporating the customizations that we would like to see. The first significant change will be use of electronically actuated flaps instead of the manual flaps that are currently in the design.

We hope that you may find some inspiration on the pages of this project!

 

Bearhawk Wing 90% Completeness

So the Bearhawk wing is 90% complete! After roughly 2 years of on again, off again work, the wing model is largely complete. The skin still hast to be modeled on the wing but that is the last major component.

Here are the renders from the model:

90% completed wing!!!

90% completed wing!!!

Aileron model

Aileron model

Winging it

Work continues on modeling the Bearhawk wing. It is ever so slowly reaching a completed state!

Hear are so more renders of the model with the aileron now properly mounted:

Top view of wing

Top view of wing

Inboard aileron hing mount

Inboard aileron hing mount

State of Modeling Today

The first step in any project is the conceptualization and design of the product. The design of the Bearhawk airplane was completed by Bob Barrows and has been maintained by him for some time. This design was completed some time in the 1990s and like all non-multimillion dollar projects from that era was designed by hand the old fashioned way.

Due to budget and location constraints construction of this project is going to be delayed for some time. It was therefore decided that in the interim the complete airplane would be constructed virtually. There were several factors that weighed into the decision to spend time modeling the complete airplane. Two of the critical items were:

  1. Mistake Mitigation – By building the aircraft virtually possible mistakes could be identified before construction began. So far this strategy has identified many small mistakes that while correctable during construction, these issues would have both time and monetary implications.
  2. Design Customization – There are several features that we would like to integrate into this design. Currently the big features are electronic flaps and a centrally mounted control stick (i.e. between the two front seats) versus two separate control columns.

To this end the last several years have been spent on and off again modelling the wing(s) for the Bearhawk. As it turns out these are the most complex items on an airplane to model!

Below is are the renders so far generated of the wing during modeling:

Main Spar
Main Spar
Wing structure
Wing structure
Wing Structure

Wing Structure

Wing with mostly complete Flap

Wing with mostly complete Flap

Wing with mostly complete Aileron

Wing with mostly complete Aileron

Flap Drive Support Frame

Flap Drive Support Frame

Flap Drive Mechanics

Flap Drive Mechanics

Flap Drive Arm

Flap Drive Arm

Aileron Hinge Support

Aileron Hinge Support

 

Wing Spar Root

Wing Spar Root

Brand New Goodness!

We are the Eastern Canada part of the Newman clan. Together we are building a home and working on a house. We are Newmans we are doers and chasers, we are children and we will raise our own with Him.

We are Christians!

The family portrait 2012!