Master Plan - 2014

Arrow II Replica Arrow Project

Fabrication Plan

Revised Mar 2014

Arrow II is an amateur built, 2/3 scale, piloted, high performance reproduction of the original CF-105. Over eight years of research were required to duplicate the proven aerodynamic shape of the aircraft before commencing construction under Canadian Recreational Aircraft legislation. While original aerodynamics have been paramount in the design of the replica, everything beneath the final paint layer has required innovative composite structural design and labour intensive mold fabrication. The following plan outlines the construction process…….

Simulator – revised Mar 2014 Construction of a computerized flight simulator was begun in 2009. Based on five separate computer modules supporting three 42” plasma screens, this simulator will be used to evaluate aerodynamic design, structural integrity, flight performance as well as being used to train flight crews. Key Goals:

Purpose

1. Examine structural stresses 2. Evaluate flight control 3. Analyze flight envelope 4. Train pilots

Major Tasks

1. Fabricate cabinet

Fab cabinet wing panels

Seal / paint wing panels

Hinge wing panels to cabinet unit

2. Install Wiring and Hardware

Mount screens

Complete wiring

Hardware cleanup

Complete programming

3. Develop Operating Manual

A. Equipment • instructions • inventory • maintenance

B. Software • Installation • inventory • Calibration

C. Program Tutorial / Menu

Fuselage Fabrication – Mar 2014

This aircraft is a composite structure comprised of the forward (cockpit) section and middle (nacelle) section external shell structures and internal duct components. The aft (engine) section to be built later is but a pair of removable access panels covering engines affixed to wing spar structures. This phase requires extensive fabrication of individual molds for composite unit parts.

Key Goals:

1. General

construction of steel jig structure to position ply formers / jig units for component molding, fabrication and joining.

2. Exterior mold Fabrication

top / bottom of cockpit shell

windshield / canopy

left / right nacelles

nacelle internal formers

cockpit-nacelle joiner D-rings

intake ramps

nose gear landing gear box

nacelle lower external shell skin

cargo bay components

3. Internal mold Fabrication

left / right intake-transition duct

engine ducts

4. Fuselage Assembly

fabrication of ply alignment jigs

installation of nose gear landing gear box

joining of canopy to cockpit

installation of nacelle interior formers

installation of cockpit joiner D-rings

alignment / fitting of major components

joining of cockpit, ducts and nacelle major units

fabrication of cargo bay

installation of nacelle lower external shell skin

Test - Fuel Tank – revised Mar 2014 A group of six small cubes representing miniature fuel tanks were constructed from aircraft grade foam and lined with various sealers. Once cured, the tanks were filled with jet fuel and set aside to test their long term ability to contain fuel without deterioration – the test tanks have been stored full of fuel since 2007 and is ongoing.

Key Goals:

1. Fabricate test cells 2. Line cells with various sealers 3. Fill with fuel – store alternately under winter / summer conditions 4. Monitor sealant performance long term

Test - Wing Spar – revised Mar 2014 Multiple test sections of various spar structural designs have been built for testing using various combinations of materials. Sections of these designs will be tested to destruction prior to a completer spar unit undergoing design limit testing.

Key Goals:

1. Design drawings 2. Layup shear web material 3. Fabricate test sections / unit structures

Test Wing Skin – revised Mar 2014 Wing skin design is evolving thru evaluation of test sections comprised of various combinations of composite materials. Designs will be tested to wing load G-force specification.

Key Goals:

1. Design drawings 2. Lay-up materials 3. Fabricate test sections / unit structures

Landing Gear Fabrication – revised Mar 2014 Development of landing gear involves engineering a new concept for this replica aircraft. The gear will be tested in accordance with operating parameters for the replica aircraft’s size, weight and general configuration.

Key Goals:

1. Nose Gear

Secure components

Complete replica design

Engineer mechanics

Fabrication drawings

Test rig

install gear / controls / up & down locks

gear doors o fabrication o installation o controls o sequencing

2. Main Gear

Secure components

Complete replica design

Engineer mechanics

Fabrication drawings

Test rig

install gear / controls / up & down locks

gear doors o fabrication o installation o controls o sequencing

3. Testing

4. Manuals

Service

Operation

Fin / Rudder – Mar 2014

A vital control element of aircraft design, the fin and rudder assembly is simple in outward appearance, but it does come under considerable stress in that it hosts a multitude of structural and mechanical components necessary to proper control of the aircraft.

Key Goals:

1. Prepare Drawings

2. Structure

Spars o Leading edge o Trailing / Hinge o Mounting flanges

Ribs

Leading edge / tip

Skin / inspection hatches

Rudder hinges / linkages

3. Electrical

Navigation lights

Electro Hydraulics

4. Manuals

Service

operations

Inner Wing – revised Mar 2014 The wing is the primary structure of the Arrow design, as it is the source of support for the weight / stresses associated with fuel load, engines, fin/rudder, main landing, the fuselage, and by extension the nose landing gear. Duplicating the original wing’s thin super-sonic 3.75% airfoil section, requires that this composite structure be extremely strong in design and tested to operating parameters for all that it supports. Key Goals:

1. Structure

Spars o Leading edge o Main o Trailing / Hinge o Landing Gear Mounts o Engine Mounts o Fin Mounts o Jack / lift points

Ribs

Leading edges

Skins / gear doors / inspection hatches

Elevon hinges / linkages

2. Electrical / Hyraulic

Conduit (Gear hydraulics,)

Brakes

Landing lights

Navigation lights

3. Main Landing Gear

(refer “Landing Gear – Main”)

4. Manuals

Service / Operation

Outer Wing – revised Mar 2014 An extension of the tapered inner wing airfoil / plan form, the composite outer wing panel becomes ever thinner. While beyond the structural stresses imposed by the main landing gear, it must, despite its thin airfoil section, have the integral strength to support its share of the aircraft wing loads and control loads.

Key Goals:

1. Prepare Drawings

2. Structure

Spars o Leading edge o Main o Trailing / Hinge

Ribs

leading edges / tip

skins / inspection hatches

Elevon control surfaces

Hinges

Control Linkages

Boost tabs / linkages

Servo Trim tabs / linkages

3. Electrical

conduit

Navigation lights

4. Pitot tube

5. Manuals

Service

Operation

Cockpit Mockup – revised Mar 2014 The purpose of building a replica cockpit is two fold; it will be used to locate equipment and controls within the confines of the interior walls of the cockpit / canopy and subsequently tested in use with the flight simulator to evaluate the aircraft’s design.

Key Goals:

1. Structure / fabrication

Seats / belts

Instrument Panels

Rudder / brake Pedals

Control sticks

Windshield anti glare panel

Canopy releases

2. Instrumentation

Airspeed

Altitude

Angle of attack

G meter

Compass

Fuel

Engines

Electrical / charging

3. Controls

Flight Controls

Engine controls

Landing gear controls

Cabin heat / ventilation

4. Electrical

Breaker panel

Switches

Instrumentation

Fuel system

Engines

Nav / landing lights

Map light / pocket

Cockpit Fabrication – revised Mar 2014 Basically a transfer of the mock-up design into the actual aircraft, the cockpit becomes the most complex area of the aircraft. Controlling every aspect of unit operation and flight, internal installations range from the comfort of seat positions, to the view, accessibility and functionality of all instruments / controls.

Key Goals:

1. General

Fill / sand interior tape joints

Cabin heat / defrost / cooling ducts

Heat / noise insulation

2. Seats

Layup new materials

Seat molds / layups

Install seats

Install seat belts / anchors

Storage compartments

3. Panel

Mold mounting flanges

fit panel

Fit instrumentation

4. Rudder pedals

Fabricate mounts

Install pedals

Route controls

5. Control Sticks

Install mounts

Install sticks

Route controls

6. Canopy

Edging

Seals

Hinges

handles

Locks

Emergency releases

Glass seals

Windshield o glare barrier o defrost

7. Electrical

Power panel / breakers

Map light / pocket

Fuel system

Gear hydraulics

Brakes

Landing lights

Navigation lights

8. Nose Landing Gear

Refer to “Landing Gear – Nose ”

9. Manuals

Service

Operation

Engine Installation and Testing – Mar 2014

While the Replica Arrow is large enough to accept a variety of turbofan engines, capital and operating costs are huge factors in the choice of jet engines. As the aircraft is by design intended for dramatic public demonstration of Canada’s iconic Avro Arrow jet, power must approximate the original aircraft’s 1:1 thrust-weight ratio - for the replica it would mean something in excess of a combined 7000 plus lbs of thrust.

Key Goals:

1. Research

2. Procurement / transport

3. Inspection / Re-build

4. Installation

Design

Drawings

5. Fabrication

Mounts

Instrumentation

Controls

Couplings

Wiring

Firewall

Hot air diffuser box

Engine By-pass Jacket

Jet pipe

6. Testing

7. Manuals

Service

Operation