Super Cool A/C – Building the Raptor Prototype

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The fore plane is almost fitted, the wings are almost painted but the air conditioning is done and working great. Other than that there is still a list of minor jobs that need to be completed before we can get the airworthiness certificate and eventually get taxi testing under way.

welcome back so second off the week could just do a little quick job that I got halfway through is these little tabs that hold the pins for the hinges in place and stop them from sliding inward they need to be drilled and tapped there into the doorframe and there are some screws to hold that in place so I just got that underway and you next thing I'm doing here is creating a little template there just on some plywood in plywood there so I can create a jig that's gonna sit on the four plane and allow us to know exactly what angle it set to and we already have the bolts that go through the spar but this will tell us that we both perfectly align the fourth of the second bolts through the forwards bar you know meanwhile Devin's working on putting all the nut plates on the hinges therefore the ailerons and rudder errs and and such so these if this is one of the rudders so he's you know drilling all those holes and then putting the nut plates on and just doing the final prep work there on the winglets in preparation for giving them their next round of primer as you can see they need some more primer on there and then he'll be working on they're spraying the rest of the wings so I zipped up two Brits and got this template cut out there on his bandsaw because we don't have a bandsaw in the hangar there at the airport anymore and this was the quickest way to do it so I got that all done and I wanted to show you that the sort of intake thing you know I bolted that up last time they're just some hardware on there and it's it's in place should handle the loads of the air coming in there given that it's just sort of directing it and there's my little template and just bolted that onto a little bit of tubo all sort of one by one tube actually not even anything at was 3/4 square tube and so that'll sit like that and then that top edge there is basically aligned with the chord line of the four plane and that way we know that it's the right angle when when we set it on the on the fuselage and Devon got the nut plates done on both of the rudders and moved on to doing the ailerons so you know those are pretty much done they could be you know bolted on to the wings once the wings are ready and so there I've got the other plate there ready to go that one this one's been drilled and tapped already so just working through that but you know other projects I'm working on as well like this one so these holes needed to be cleared out there for where the push rods are the actuator rods for the elevators they're on the four plane so and I had to do that carefully and slowly because there's a movement in the way it sort of goes through its travel there and you know you want to know one to create like an overly large hole not the hole obviously isn't just a straight line because of the way the bell crank moves anyway so it took a little while to do that and then the other one was a little bit quicker so that those done and bolted that Hardware in there and he could see Jeff is just a bit ready there to spray both of those wing nuts and get them coated and the rest of the wings obviously been done but just need that second coat to be put on there so making progress slowly but surely and I must say we've been pretty fortunate with the weather since we moved into this hangar we haven't had any days where we wouldn't haven't been able to work outside and he's Devin just working on now putting their nut plates here on the ailerons and just using the little rivet driver thing that we have Ribit press thing one that I used a long time ago when I was doing that plates on various different things so he's pretty much got the handle or the hang of this not having too many problems just he had I think 50 plates 50 nut plates to put on so anyway get those down in there so now that those are all done because you've got those all finished before the end of the day Friday and now that they're all done they can be bolted on to the wings so just waiting on the wings to be finished now and so here's these bellcrank things there and with the push rods so I put the final hardware in there and that little bit of tape in there was just to help hold the the washers in place because I needed some washers in between the little zero the bell crank but got the travel that we're looking for there and the actions nice and that so hopefully it all works out for us there there's the other one so took a while to do that to get those sorted out but now that they're done it's just another job that I can tick off the list they want to move their Center bellcrank there you can see both of them sort of move in unison so that's obviously how it's supposed to work and actually had that Bell crank around the wrong way the center one so that'll be coming off there and being switched around and so Jeff got the winglets ear painted both sides of those this is the Thursday afternoon yeah got those painted so the next thing was just basically to paint the upper skins and also the lower skins of the wings here and so my next job on the four plane was to just switch out and put the correct hardware in for all the hinge bolts because we just had a couple of temporary bolts in there so I put like a wide-area put a wide-area washer on the end where the bearing is and then put the bolt through that and then so the ball goes through the washer and then the bearing and then the other side of the hinge the one that's mounted to the elevator and then just a normal washer on there and then a nighlok locking nut so I had to do those but you know didn't take long to do those and so then having done that it was time to get the fuselage ready so I could actually mount the four plane and this is the first time that it's going back on to the fuselage since the lower skins were bonded into play and so we don't have like a perfect fitment yet in how it sits into the fuselage so having that you know not fitting correctly just yet means that you know I have to spend some time to go and fit that in there and then obviously the bolts that run through the forward bulkhead I've got to put those through and make sure that they you know meet up with the the holes and also the nut plates that are embedded into the spire there of the of the four plane and you know get those bolted in and then we have to check the angle on there with that little jig that I created and make sure that we're we're we're supposed to be for the angle because you know you want the four plane to be several degrees higher angle of attack than what the main wing is so it definitely always stalls first you know anytime you get the aircraft slow because you don't want the main wing to ever store on this aircraft and the four plane will always store first and drop the nose it's you know the whole premise of the Qunari aircraft and why you know in some ways it's a safer aircraft to fly because you're not gonna get yourself in a stall spin situation so anyway I've got those I got that hardware in there and and then it was time to put the four plane up on to the fuselage and spend another couple of hours there getting it right and if you haven't sort of picked up on it yet man composite work especially for prototyping is just a lot of fit and finish fit and finish fit and finish and it gets gets old real quick you've been doing it for several years now so here's a Jeff and Devon just doing the final wipe down on the upper surfaces of both of the wings there in preparation for putting the last and around a primer on those and as usual the weather cooperating for us a nice sunny day and just light wind and perfect for painting outside actually and so there's the fuselage now with the four plane just sort of sitting place and you know yet to actually get the bolts through from the forward bulkhead still as I said got to do some fitment on there to get it to sit down exactly the way it's supposed to you can see it's kind of sitting a little bit high there on the leading edge but I had to sort of stop what I was doing there because the AC guys were showing up again to check the AC on the aircraft and here you can see Jeff got both of the upper surfaces of the wings primed but there wasn't enough time in the day for them to dry completely in order to be able to flip them over and paint the bottom side so unfortunately the bottom side is gonna have to wait till Monday now but not a big deal cuz you know we'll get the wings on next week and so here's how you see guys showed up you know you know got the system all you know checked out and gassed up again and started working actually great when I first turned it on and then I was like well now it's not getting cold anymore it's getting hot and so after a little bit of thinking and messing around I figured out what was going on so that the AC and it's working great but then also the heater was on and it was working great too so we I clamped off the heater hose and then the ACS worked great as you could see it's pumping out their 44 degrees and actually had it down to 43 degrees that's Fahrenheit so it was pumping out some super cold air and working really well Missy have the engine running they're up the idle for when the air conditioners on it and 1200 rpm and I'll probably adjust that again but that seems to work fine and we hadn't run in for quite a long time we came up to full temperature and a 1200 rpm but just sat there and got you know those temperatures there and stabilized so pretty happy with how the engine cooling is working and there's the pressure gauges there on the system after we shut the engine down so yeah that AC is working great now so that I just got to fix the heater thing and this is what I ended up doing so I just put a clamp on this hose here and because that's the outflow hose from the top of the engine with a heated you know cool and it runs down into the cabin so I put a clamp on there to stop that but really what I need is you see this valve is supposed to be in here and that basically shuts off the flow to the in the cabin unit and this is the valve here and I never actually installed it and I think back when Dan was here I think for some reason we just decided we didn't need that but apparently you do need it because what was happening was the heater was turning on and just staying on when the a/c was on though both both just fighting with each other and so what I have to do it's just actually a real quick fix I just have to cut the heater hose under here and you'll see there's the two hoses that run up to the unit under the dash just have to cut that one there and insert this this little valve and then plug that plug in there that was you know an existing plug coming from the unit and already tested it and it just shuts and opens and shuts the valve there depending on what the ACS hit – so when the AC comes on you set the temperature the valve shuts and no hot water will flow around the system so it's gonna be actually one of the quickest fixes I've had in a long time and so those guys left I managed to do some more work on the four plane here and getting it closer so I went in in about a half a degree of getting it set up just right there and I still don't have the bolts going through correctly so that's going to be my job from Monday to get those bolts sort of firmly in place but you know now the elevators are on in the hard way that's all done you know we're getting closer with the fall plane won't take more than a day to get it sorted out here so there you can see when I push down on it I get close to the angular one which is basically six degrees six point six right now so yeah just need to do a little bit more fearing out there and I'll get that in place and for anybody who wants to know there's the drain line for the condensation for the air conditioning system just got to go on into a bottle right now now I'll have to figure out something later here to do that anyway here's a look there with the doors on and the fall plane on the also their nose hatch door doesn't close down completely just yet because that needs to be cleared a little bit but I can't do that until the fall plane is nicely bolted in place but other than that things are coming along pretty good got the DAR coming sometime next week I haven't had a confirmation from him yet and as I said our test pilot is gonna show up the following weekend and take a look at what we got so yeah we're getting pretty close Williams will be on next week for plane will be finished next week and a few other little projects and stuff I still got to do but oh we're getting there anyway that's our video for this week and thanks again for tuning in and I will catch up with you next week on Tuesday

33 thoughts on “Super Cool A/C – Building the Raptor Prototype”

  1. Re: the heater tap. Lots of new cars and trucks have a single unit that stops both the line into the heater and the line out. You may have less of an issue because of the line length but I needed to put a stop on the return as well to stop engine coolant heating up all the way back to the heater core. When I did that I had no more overheated cabin on a day when you didn't need either heating or cooling.

  2. Is it possible to detail the main differences between the Velocity and the Raptor? I think some will make an unfair comparison, like airfoils, engines, etc. The Raptor is in many, but maybe not all ways, an improved, modernized alternative. I personally think the comparison would be a good marketing tool.

  3. I know you're doing this already, but sure to check the canard incidence with the aircraft level. Level the aircraft, check incidence, double and triple check both. Very important! Looks great, Peter!

  4. Incredibly exciting! Just as an individual data point, I’d personally be very interested in an aluminum-built Raptor even if performance suffered a little, if that kept costs and build-time low!
    Keep up the great work!

  5. lol at heater valve – I build cars and I've been there. If it were me, though, the valve would have been there and closed then I'd wonder why I couldn't get the system to work due to air being trapped in that line…. point is, of all the things to do "wrong", you may have actually saved yourself from a larger, harder to find problem… which of course, means you did it on purpose. You're clever 🙂

  6. Looking good. The nuts on the aileron linkage don’t need lockwire to prevent backing out? Is nylon locking nuts sufficient?

    Noticed the nuts on the intake air deflector also were just nylon lock nuts with no lock wire. Could engine vibrations potentially cause backing out and then have loose FOD in the engine bay?

  7. Well, I would say that it would appear that your stress levels are beginning to return to near normal, with some of the more fiddly bits coming together now. looking good. Enjoyed it.

  8. Wow. I cant believe your this close to the maiden flight! You guys are amazing! Glad we have had the oppritunity to follow along and see it come to this point! Shes a beauty! Thanks for the update cant wait for the next one!

  9. At 13:00, it looks like the rear portion of the alignment template is not properly seated on the trailing edge of the foreplane for the angle measurement. You probably knew that but just wanted to make sure.

  10. I love your project. I wish airstrips here where i live would be longer for pusher airplane but we have only 600m airstrip with no place to expand – town at one end and river+mountain behind at other end. Place is beautifull with amazing chimneys for soaring in gliders but no place for canard pusher 🙁

  11. Peter will that foreplane lay directly on the fuselage and the hatch door also diretly on the foreplay? will there be some play to accommodate for possible flexing of the foreplane? will you use some rubber seal to avoid chaffing? I am not an engineer and have never built an aircraft but have admired your perseverance over the last 2 years.. congratulations on your achievements.

  12. I've been watching you guys build for the past few years and it is getting exciting. Looking great and it seems like it is working great. Can't wait to see her take to the air. Hope you making it up to Oshkosh.

  13. I saw the earlier comment about nylocks on the rotating hinge parts and agree with that assessment.

    I noticed at 1:54 nylock AN 365 or 364 being used on the air plenum “ramp”.

    I was always taught to avoid polymer elastic nuts in the engine cowl due to heat issues.

    A better solution would be AN 363 (MS-21045) metal split stop-nuts.


  14. You could put the AC condensation to a catch can with a float so when it’s full, the float opens a drain to outside. When it’s not full, the drain is closed so you don’t leak cabin pressure. That’s how the galley sink drains work on the aircraft I work on.

  15. 6.6 degrees compared to what, where is your baseline? You explained the objective of the fitment work very well, as getting proper angle of attack delta to the wing. But the wing is not on. So where are you measuring from?

  16. Endless details. Your persistence is to be admired. AC condensation catch tank with drain overboard. You could have valve open when not pressurized or orifice to minimized pressure loss.

  17. I have been watching from day 1, you have come so far! I am a little concerned how complex this project has been. I would suggest that you contact an aviation industrial engineer in order to streamline the manufacturing and building process. The weakest link here is going to the manufacturing of the kit and lengthy build process. If you can make the manufacturing and building time comparable to Vans Aircraft, I think you have a real shot at this aircraft enduring thru the generations

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