Hi.  One of my abiding challenges in this design is ensuring that the engine will fit in the nose.

I have a Generac 990 v-twin which I got from Valley Engineering when Gene was still there, and they were making engines.  Mine is the “Big Bad Twin” – a bored-out, tricked up version of the 35-odd HP original motor.  Mine pushes out 50hp, and weighs 53kg complete with twin exhausts, starter, AND redrive.  That’s a pretty sweet package.  I haven’t removed these items to weigh the bare engine, but I hope to do so soon.

However, I can’t find an accurate 3D rendering of the engine, and herein is my problem:  how to I sculpt the nose of the plane to ensure that the engine will fit?  If I had better CAD tools (or knew how to drive them better) I’d probably be able to do so.  But I don’t.  So here’s what I’ve decided to do:

I will build the firewall forward section of the fuselage (using the first seven formers only).  Then I’ll cover them with 3mm EPS foam from the local hobby shop.  That will achieve the following:

  1. The materials will be extremely cheap
  2. I can iterate the nose design indefinitely till I get it right
  • The first stage of the process is to mount the firewall forward formers on the strongback, and lay the foam strips – just as I would do using the Paulownia strips.  (Great practise, too).
  • Then I need to build an engine stand and mount the engine (see the accompanying pic)
  • Finally, I’ll take the two halves of the nose section, and attach them to the engine stand.  The engine will either fit, or it won’t.  If it fits, I’ll pop a bottle of Champers.  If not, the champagne will stay in the fridge, and I’ll return to the CAD and amend the volume of the nose till I get it right.

The engine stand will be on castors so I can move it around, and will have the bed-mount for the engine added to what you can see here.  Also – notice that the entire thing fits together without bolts or screws.  This means when I no longer need it, I can break it down and flat-pack it against a wall somewhere…  Construction material:  18mm plywood.