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#4468725 - 04/03/19 03:02 PM OT - Fokker pair No.2  
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Hi all,
The first of the Fokker D.VII pair is completed.
So now I'm starting the second of the models, the 'skeletal' model.
This will be a full view model with 3D printed parts from 'Shapeways'.

The donor engine is from the 'Wingnut Wings' Fokker D.VII (OAW) built with the following replacement 3D printed components:
Created by Bob Monroe ('Flugzeugwerke') and available from ‘Shapeways’.
Mercedes D.III Oil Pump,
Mercedes D.IIIa Cylinders (hollow),
Mercedes D.IIIa Crankcase,
German Aircraft Magneto,
Mercedes Cylinder clamps,
Gun synchro mechanism,

The aircraft structure will be the 3D printed Fokker D.VII structure.
Created by Richard Andrews ('Aviattic') and available from ‘Shapeways’.

Shapeways

There will be other after market parts used.

I thought I'd start with the engine, which had to modify slightly as the internal mountings in the 3D sump and block are too small to accept the kit supplied propeller shaft.
Instead I've made one from brass micro-tube to fit not only the 3D engine but also the 'Proper Plane' Heine propeller.

Mike

[Linked Image]

[Linked Image]

[Linked Image]

Last edited by Sandbagger; 04/08/19 08:37 AM.

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#4468740 - 04/03/19 05:44 PM Re: OT - Fokker pair No.2 [Re: Sandbagger]  
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Hi Mike, The linked images are not showing for me.


Insanity: doing the same thing over and over again and expecting different results. A. Einstein

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#4468758 - 04/03/19 07:44 PM Re: OT - Fokker pair No.2 [Re: Sandbagger]  
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I forgot my site host servers are undergoing maintenance (yesterday and today) - hopefully my images will show up by tomorrow,

Mike


RAF (27 years)
Aerospace Technical Author/Editor (20 years)

Mikes WW1 Aircraft Models
http://igavh2.xara.hosting

Alienware Aurora R5
Windows 10 64 bit
Intel i7-6700K 4.2Ghz (liquid cooled)
Two GTX 1080 Foundations in SLI (8 Gig each)
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#4468770 - 04/03/19 09:59 PM Re: OT - Fokker pair No.2 [Re: Sandbagger]  
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Those are beautiful models. Especially that HANSA-BRANDENBURG W.29. Thanks for the link. Enjoyed them all.

#4468848 - 04/04/19 01:16 PM Re: OT - Fokker pair No.2 [Re: Sandbagger]  
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Ah, now the links are working!


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#4468862 - 04/04/19 03:27 PM Re: OT - Fokker pair No.2 [Re: Sandbagger]  
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Error 503 on the host server - apparently the ISS pool had to be refreshed 

OK now,



Mike


RAF (27 years)
Aerospace Technical Author/Editor (20 years)

Mikes WW1 Aircraft Models
http://igavh2.xara.hosting

Alienware Aurora R5
Windows 10 64 bit
Intel i7-6700K 4.2Ghz (liquid cooled)
Two GTX 1080 Foundations in SLI (8 Gig each)
32 Gig DDR4 2133Mhz
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34" Dell Ultra Sharp U3415W (3440x 2440)
CH Pro-Pedals, Stick and Throttle
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#4468911 - 04/04/19 07:34 PM Re: OT - Fokker pair No.2 [Re: Sandbagger]  
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Hi all,
A few more engine bits prepared.
Spark plugs made from micro-tube and 'RB Motion' aluminium nuts.
'Taurus' manifold locking rings - cut and sanded to fit the 3D printed engine,

Mike

[Linked Image]

[Linked Image]

[Linked Image]


RAF (27 years)
Aerospace Technical Author/Editor (20 years)

Mikes WW1 Aircraft Models
http://igavh2.xara.hosting

Alienware Aurora R5
Windows 10 64 bit
Intel i7-6700K 4.2Ghz (liquid cooled)
Two GTX 1080 Foundations in SLI (8 Gig each)
32 Gig DDR4 2133Mhz
1TB SSD boot drive - 1TB SATA storage drive
5.1 Surround Sound
34" Dell Ultra Sharp U3415W (3440x 2440)
CH Pro-Pedals, Stick and Throttle
TrackIR-5 Pro
#4469055 - 04/05/19 04:19 PM Re: OT - Fokker pair No.2 [Re: Sandbagger]  
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Hi all,
A couple of magnetos each made of four separate 3D printed parts.
The ignition leads support tube made from micro-tube.
The magneto drive modified to fit the 3D engine with a brass rod for the magneto drives.
Also the cylinders are mounted onto the engine block,

Mike

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]

Last edited by Sandbagger; 04/06/19 09:09 AM.

RAF (27 years)
Aerospace Technical Author/Editor (20 years)

Mikes WW1 Aircraft Models
http://igavh2.xara.hosting

Alienware Aurora R5
Windows 10 64 bit
Intel i7-6700K 4.2Ghz (liquid cooled)
Two GTX 1080 Foundations in SLI (8 Gig each)
32 Gig DDR4 2133Mhz
1TB SSD boot drive - 1TB SATA storage drive
5.1 Surround Sound
34" Dell Ultra Sharp U3415W (3440x 2440)
CH Pro-Pedals, Stick and Throttle
TrackIR-5 Pro
#4469227 - 04/06/19 05:27 PM Re: OT - Fokker pair No.2 [Re: Sandbagger]  
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Hi all,
Starting to assemble the engine accessories now.
So far the spark plugs, ignition lead support tubes, camshaft, air pump, coolant drain tap and cylinder base bridging clamps.
Still plenty more to do,

Mike


[Linked Image]


[Linked Image]


RAF (27 years)
Aerospace Technical Author/Editor (20 years)

Mikes WW1 Aircraft Models
http://igavh2.xara.hosting

Alienware Aurora R5
Windows 10 64 bit
Intel i7-6700K 4.2Ghz (liquid cooled)
Two GTX 1080 Foundations in SLI (8 Gig each)
32 Gig DDR4 2133Mhz
1TB SSD boot drive - 1TB SATA storage drive
5.1 Surround Sound
34" Dell Ultra Sharp U3415W (3440x 2440)
CH Pro-Pedals, Stick and Throttle
TrackIR-5 Pro
#4469240 - 04/06/19 06:52 PM Re: OT - Fokker pair No.2 [Re: Sandbagger]  
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Looking good Mike. Can you explain the difference between resin and 3D printed parts? I assume you went with 3D printed because they’re better. Are they more detailed? Or is it because they could be printed on demand and thus more readily available? Just wonderin’.


"Take the cylinder out of my kidneys,
The connecting rod out of my brain, my brain,
From out of my arse take the camshaft,
And assemble the engine again."
#4469318 - 04/07/19 08:19 AM Re: OT - Fokker pair No.2 [Re: Sandbagger]  
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Normally a kit will be created using styrene ('plastic'), which can vary dependent on who makes the kit. The two halves of the sprue mold are machined from steel and styrene under pressure is pumped into the mold, which when separated ejects the parts sprue.
Some styrene is harder and therefore can be more defined in detail. Also these kits normally have location pegs and holes, so alignment of parts is not a problem. Parts are cemented using styrene cement, which melts and welds surfaces together.
Resin kits are made either as production runs or as short runs and, like sand casting, use master patterns to create the molds (similar to vacuum molded kits) in which the resin is poured. Those companies that retail resin as standard, such as HPH Models, are usually of better quality than those from short runs, which can have more problems, such as warping, small air blow holes and mis-molding (short shot). I have some resin parts which are obviously created in a small one man workshop. Some resin kits have no locating pegs or holes so can prove tricky to align parts and parts need to be cemented using CA adhesive, which bonds surfaces together, as styrene cement has no effect on resin.
The new comer is 3D printing, which although it has come a long way, still has its limitations. Various materials are used but for the parts I'm using, acrylic is the base material.
Expense is one disadvantage and small parts can be brittle (dependent on the material used) and even fine printing still leaves 'layer lines' on the surfaces.
However, printing from CAD type design software can produce small and detailed parts. For example look my earlier shot of the 3D printed engine block compared to the kit supplied part.

As the exposed structure for this model is 3D printed, I thought I'd try the 3D printed engine parts available as well.
So far I'm quite impressed with the level of detail although the surface 'layer lines' are evident on close inspection. They can be sand or scrapped away, but this is not really a practical option when working with small complex parts,

Mike


RAF (27 years)
Aerospace Technical Author/Editor (20 years)

Mikes WW1 Aircraft Models
http://igavh2.xara.hosting

Alienware Aurora R5
Windows 10 64 bit
Intel i7-6700K 4.2Ghz (liquid cooled)
Two GTX 1080 Foundations in SLI (8 Gig each)
32 Gig DDR4 2133Mhz
1TB SSD boot drive - 1TB SATA storage drive
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34" Dell Ultra Sharp U3415W (3440x 2440)
CH Pro-Pedals, Stick and Throttle
TrackIR-5 Pro
#4469350 - 04/07/19 01:00 PM Re: OT - Fokker pair No.2 [Re: Sandbagger]  
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Mike, thanks for this thorough explanation. Imagine one day when we all will be able to 3D print parts for our models right at home. I suppose one day they’ll come up with a way to eliminate the layer lines. Probably increase the resolution to a level that is indiscernible to the human eye. Technology!


"Take the cylinder out of my kidneys,
The connecting rod out of my brain, my brain,
From out of my arse take the camshaft,
And assemble the engine again."
#4469375 - 04/07/19 04:32 PM Re: OT - Fokker pair No.2 [Re: Sandbagger]  
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Hi all,
The engine has progressed a bit more now with the addition:
The conical valve springs
Crankcase breather pipe
Magneto drive assembly with two 3D printed magnetos
Two air pump to crankcase pipes
Decompression valve.

Still have to add ignition leads, intake manifold with locking rings, water pump, coolant pipes, oil filler pipes, sump oil sight glass.
There's also a couple of other pipes plus engine controls.

Mike

[Linked Image]

[Linked Image]


RAF (27 years)
Aerospace Technical Author/Editor (20 years)

Mikes WW1 Aircraft Models
http://igavh2.xara.hosting

Alienware Aurora R5
Windows 10 64 bit
Intel i7-6700K 4.2Ghz (liquid cooled)
Two GTX 1080 Foundations in SLI (8 Gig each)
32 Gig DDR4 2133Mhz
1TB SSD boot drive - 1TB SATA storage drive
5.1 Surround Sound
34" Dell Ultra Sharp U3415W (3440x 2440)
CH Pro-Pedals, Stick and Throttle
TrackIR-5 Pro
#4469501 - 04/08/19 01:10 PM Re: OT - Fokker pair No.2 [Re: Sandbagger]  
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Hi all,
The 3D printed parts are detailed but as can be seen from the shot below, some are very small.
This is a pair of machine gun synchronization mechanisms, each made up of four separate parts.
The biggest problem is separating them from the base block without damaging them!!

Mike


[Linked Image]


RAF (27 years)
Aerospace Technical Author/Editor (20 years)

Mikes WW1 Aircraft Models
http://igavh2.xara.hosting

Alienware Aurora R5
Windows 10 64 bit
Intel i7-6700K 4.2Ghz (liquid cooled)
Two GTX 1080 Foundations in SLI (8 Gig each)
32 Gig DDR4 2133Mhz
1TB SSD boot drive - 1TB SATA storage drive
5.1 Surround Sound
34" Dell Ultra Sharp U3415W (3440x 2440)
CH Pro-Pedals, Stick and Throttle
TrackIR-5 Pro
#4469503 - 04/08/19 01:21 PM Re: OT - Fokker pair No.2 [Re: Sandbagger]  
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The engine looks fantastic Mike! Keep us posted on what tools you used to separate the 3D printed matter. If the material is dense in nature it could be problematic. Knife or saw!!

Last edited by Robert_Wiggins; 04/08/19 01:22 PM.

(System_Specs)
Case: Cooler Master Storm Trooper
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Mem: Corsair Vengeance (2x 8GB), PC3-12800, DDR3-1600MHz, Unbuffered
CPU: Intel i7-4770K, OC to 4.427Ghz
CPU Cooler: Cooler Master Seidon 240M Liquid CPU Cooler
Vid Card: ASUS GTX 980Ti STRIX 6GB
OS and Games on separate: Samsung 840 Series 250GB SSD
Monitor: Primary ASUS PG27AQ 4k; Secondary Samsung SyncMaster BX2450L
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#4469521 - 04/08/19 06:10 PM Re: OT - Fokker pair No.2 [Re: Sandbagger]  
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Trouble is the acrylic material used tends to be brittle so is very difficult to remove without damaging it,

Mike


RAF (27 years)
Aerospace Technical Author/Editor (20 years)

Mikes WW1 Aircraft Models
http://igavh2.xara.hosting

Alienware Aurora R5
Windows 10 64 bit
Intel i7-6700K 4.2Ghz (liquid cooled)
Two GTX 1080 Foundations in SLI (8 Gig each)
32 Gig DDR4 2133Mhz
1TB SSD boot drive - 1TB SATA storage drive
5.1 Surround Sound
34" Dell Ultra Sharp U3415W (3440x 2440)
CH Pro-Pedals, Stick and Throttle
TrackIR-5 Pro
#4469847 - 04/10/19 08:04 PM Re: OT - Fokker pair No.2 [Re: Sandbagger]  
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Hi all,
The end is in sight for this engine build.
I've added the decals, ignition leads, gun synchronization mechanism, oil sight glass, generator and drive, cylinder fuel primers, water pump, intake manifold with locking rings, crankcase breather pipe and additional pipes.
All that's left is to add the engine mounted throttle and spark advance (ignition timing) controls - the remainder of the control runs can't be added until the engine is fitted into the fuselage (with the cockpit),

Mike


[Linked Image]

[Linked Image]


RAF (27 years)
Aerospace Technical Author/Editor (20 years)

Mikes WW1 Aircraft Models
http://igavh2.xara.hosting

Alienware Aurora R5
Windows 10 64 bit
Intel i7-6700K 4.2Ghz (liquid cooled)
Two GTX 1080 Foundations in SLI (8 Gig each)
32 Gig DDR4 2133Mhz
1TB SSD boot drive - 1TB SATA storage drive
5.1 Surround Sound
34" Dell Ultra Sharp U3415W (3440x 2440)
CH Pro-Pedals, Stick and Throttle
TrackIR-5 Pro
#4469969 - 04/11/19 02:33 PM Re: OT - Fokker pair No.2 [Re: Sandbagger]  
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Mike

I guess you were able to cut the 3D printed parts without damaging them. The engine looks really impressive.

What kind of tool did you use to separate the 3D parts from their base?


(System_Specs)
Case: Cooler Master Storm Trooper
Pwr Sup: OCZ, GameXStream,1000-Watt
MB: Asus Maximus VI Extreme
Mem: Corsair Vengeance (2x 8GB), PC3-12800, DDR3-1600MHz, Unbuffered
CPU: Intel i7-4770K, OC to 4.427Ghz
CPU Cooler: Cooler Master Seidon 240M Liquid CPU Cooler
Vid Card: ASUS GTX 980Ti STRIX 6GB
OS and Games on separate: Samsung 840 Series 250GB SSD
Monitor: Primary ASUS PG27AQ 4k; Secondary Samsung SyncMaster BX2450L
Periphs: MS Sidewinder FFB2 Pro, TrackIR 4

#4470108 - 04/12/19 08:32 AM Re: OT - Fokker pair No.2 [Re: Sandbagger]  
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Hi Rob,
Yeah I used a fine modelling saw to cut away most of the base block then carefully sanded the rest off.
Bob Monroe, who created the parts, suggested a saw from 'RB Productions and fixing the base block to something larger so it was easier to hold whilst cutting it away, but I'd already done it by then.
I have that saw coming though, for future use,

Mike'


RAF (27 years)
Aerospace Technical Author/Editor (20 years)

Mikes WW1 Aircraft Models
http://igavh2.xara.hosting

Alienware Aurora R5
Windows 10 64 bit
Intel i7-6700K 4.2Ghz (liquid cooled)
Two GTX 1080 Foundations in SLI (8 Gig each)
32 Gig DDR4 2133Mhz
1TB SSD boot drive - 1TB SATA storage drive
5.1 Surround Sound
34" Dell Ultra Sharp U3415W (3440x 2440)
CH Pro-Pedals, Stick and Throttle
TrackIR-5 Pro
#4470153 - 04/12/19 04:32 PM Re: OT - Fokker pair No.2 [Re: Sandbagger]  
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Robert_Wiggins Offline
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Originally Posted by Sandbagger
Hi Rob,
Yeah I used a fine modelling saw to cut away most of the base block then carefully sanded the rest off.
Bob Monroe, who created the parts, suggested a saw from 'RB Productions and fixing the base block to something larger so it was easier to hold whilst cutting it away, but I'd already done it by then.
I have that saw coming though, for future use,

Mike'


Would that saw have been produced through a photo etch process. I understand that is a common approach for very thin craft saw blades.


(System_Specs)
Case: Cooler Master Storm Trooper
Pwr Sup: OCZ, GameXStream,1000-Watt
MB: Asus Maximus VI Extreme
Mem: Corsair Vengeance (2x 8GB), PC3-12800, DDR3-1600MHz, Unbuffered
CPU: Intel i7-4770K, OC to 4.427Ghz
CPU Cooler: Cooler Master Seidon 240M Liquid CPU Cooler
Vid Card: ASUS GTX 980Ti STRIX 6GB
OS and Games on separate: Samsung 840 Series 250GB SSD
Monitor: Primary ASUS PG27AQ 4k; Secondary Samsung SyncMaster BX2450L
Periphs: MS Sidewinder FFB2 Pro, TrackIR 4

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