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ERacer Aircraft Construction Website

Our Goal: To safely build and fly the ERacer
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ER CONSTRUCTION LOG
Chap 1-4 Fuselage
Chap 5 Nose Structure
Chap 6 Main Spar Construc
Chap 7-8 Cabin and Contro
Chap 9 & 13 Canopy/TDeck
Chap 10 Landing gear Syst
Chap 11 Wings and Winglet
Chap 12 Strakes and Fuel
Chap 15-16 Canard Constru
Chap 17-18 Engine Install
Chap 19 Cowling Construct
Chap 20A Surface Finish
Chap 20B Painting
Chap 21 Panel and Electri
Chap 22 FAA Inspection
Chap 23 Flight Testing
ERacer Landing Gear Kit
Eureka Wing Cores
ERacer Merchandise
Canard Covers by Doroth
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Shirl Dickey's ERacer
Tom Koftinoff's ERacer
Erik Frank's ERacer
Cliff Cady's ERacer
Bruce Vinnola's ERacer
Rob Orsolits' ERacer
Tore Bjoelgerud's ERacer
Mitch Hargin's ERacer
Mark Fisher's ERacer
Andre Rousseau's ERacer
Tommie Turner's ERacer
Kim Riley's ERacer
Daniel Muller's ERacer
David Hanson's Canard X
Joel Aubry's ERacer
Jack Morrisons ERacer
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Chapter 1 - 4,    Fuselage Assembly
 
 
Left:  The primary epoxy system for my ERacer was Aeropoxy 2032/3660
Right:  My epoxy ratio pump.  I used a 60watt bulb and a cover box to keep things warm in the winter.
 
Left:  I started with the Bulk head chapter.  This was the first bulkhead that I completed so many years ago.
Right:  The Divinicell Foam fuselage sides..I first started using a knife to carve it out but quickly changed to a router for a much smoother surface.
 
Left:  This shows the wood stringer being bonded to the fuselage side and the foam being curved to shape prior to glassing over all of it.
Right:  My daughter standing by a completed fuselage side. 
 
 
Left:  A trial fit of the fuselage sides positioned with the firewall bulkhead.
Right:  The fuselage sides being epoxied together with front bulkhead, instrument panel, and seatback.  The structure is held together with braces and large rubber bands.  The Firewall is not glued in at this time.
 
Left:  This is the 3" foam being carved out to form the fuselage bottom.
Right:  Starting the initial glassing of the bottom foam.
 
 
 
    
Left:  After the bottom is glued into position,  We flip it on its side to begin the shaping.
Right:  Now the aircraft has entered what we call the "boat stage".  All your friends and neighbors will think you are building a boat. 
 
 
Here are two similar shots,  the left with out the outer glass skins and the right one after laying the glass on the outside of the fuselage.
 
Left:  re-inforcement tapes are glued in to further connect the bulkheads and the fuselage sides.
Right:  I chose to mount a throttle hardpoint on the left side of the fuselage  Note the trim lever in position and seatbelt hardpoint on the lower stringer.
 
 
 
 
Left:  The throttle quadrant, trim lever and main control stick installed as well as the covers over the seat.  there is a small area under each seat for storage.
Right:  Control stick 
 
 Pic showing left consul installed.
 
 
 Seat back head rests with shoulder harness hardpoints installed into fuselage.
 
The firewall is made of Bi-directional layers of glass and epoxy over Aircraft grade plywood covered in fiberfrax and then Aluminum sheet.
 
 
Forward side of firewall after installation with aileron cables routed through. 
 
 
 
Aft side of firewall with engine mount installed as well as the rudder cable pulley mounts. 
 
 
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The Upper fuselage assembly is covered in the " Chapter 9 & 13 " tab.