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Maule scratchbuild

Old 03-09-2009, 10:34 PM
  #1  
PMcIntire
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Default Maule scratchbuild

It's been a while since I've started a thread. In a week or two, I'll be finishing up plans that approximate the shape of a completely scratch built Maule Orion semi-scale. I've had the plans that I've drawn up gradually since I believe about 2 years ago.

Motor is a deeply geared 16/15/3 Mega Motor brushless on what will likely be a 3S lipoly or a 4s A123 pack. 6 channels, rudder, elevator, throttle, ailerons with reflex, and flaps. Light balsa contruction is planned, and it will be a gentle aircraft, not too hot, and not too sedate. Should be nearly the same size as a .40 model. Most likely going to be a tail dragger. No pictures of the plans will be up until I have them finished. I think this thread will help me hold to a schedule and actually get the thing done.

Last edited by PMcIntire; 07-11-2009 at 04:24 AM.
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Old 03-10-2009, 06:18 PM
  #2  
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I always got a giggle out of Maule's designs. At least you won't need a runway! Have you selected your gearbox and prop size(s) yet?
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Old 03-11-2009, 09:45 PM
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I decided on the gear and prop size about a year and a half ago. I think I have something like 6:1, 7:1, unusually deep for most setups. I'm swinging a big prop so it'll be a bit slower (15 incher at around 5k-6k rpm if memory serves me right), but It will have a fair amount of static thrust. I will also have a very efficient propeller. These mega motor 16/15/3 motors can handle an awful lot more than you might think. Given the right gearbox, you can run a 6s-8s setup. Stay under 45 amps and get plenty of cooling, and you'll be alright. My math said I'd be pulling around 30 amps static if I remember correctly, probably 20 amps in flight in a strong climb. An interesting side note, I went with a full scale fuselage in this model, so by my improper English that means the wings should still be inside the cabin. Actually, I just mean the fuselage will be a unique detail to the model, as it will be larger than those on some .40 size models. The fuselage will not have a whole lot of detail on the inside, however it will have the unusually large window doors the characterize some of the aircraft Maule has released. I think I went with the long nose similar to how the turbine version looks. Not sure though, have to dig up the plans a bit. I only have the rudder and elevator left to draw, next I'll be making a parts list and headed off to the store. I have a nice scroll saw (DeWalt) for cutting out the parts. I'm pretty excited to get to use it for a model... finally!
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Old 03-26-2009, 10:55 PM
  #4  
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Alright, the penning is complete and I ran over to staples, got 2 sheets copied AND a digital copy for less than 10 dollars. Not bad! I'd upload the file here, but the file size is too great. Several lightening holes will be made with a scrollsaw, I will probably add more ribs, perhaps some 3/8" x 1/16" balsa strips capping over the 1/16" spars, simplification of unnecessary detail, etc.

I have both PDF and jpg images.

Here, I re-sized the jpeg so there is at least a picture to see:

BTW, the image I was scaling from was not a Maule Orion, it was a Maule M-5... oh well.

8/24/2018: Plan copies are no longer available for digital download.
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Old 06-06-2009, 11:15 PM
  #5  
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Ok, building time is around the corner and I have a pile of wood waiting to be turned into a model. I'd most a picture, but it's just a bunch of balsa sticks. Nothing that interesting. As I am limited on space I will start by building the elevator and rudder first, while I usually start kits by building the fuselage first then the wing. Totally reversing the order this time around! Look forward to a few pictures in the coming days.
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Old 07-09-2009, 05:01 AM
  #6  
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All the balsa has arrived, and we're off to a start:

Left wing is mostly done, with carving, a spar system and covering left to do... I will probably use an aluminum tube for the spar, and a pin to lock the trailing edge into location. The build is heavier than I anticipated... should still have plenty of power left in the motor.

The image used a flash in the dark, next pictures should look better.
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Old 07-09-2009, 06:28 AM
  #7  
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And about 1.5 hours later, the other wing is built:
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Old 07-09-2009, 10:09 PM
  #8  
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Fuselage is taking shape, I'm taking a break for a few hours to vent any frustration with building the fuselage. It's going together fine, nice and sturdy.

I really should use waxpaper....

I am probably taking the rest of today off. Only so much intricate cutting I can do. Rudder and elevator, no problem. BTW, notice the paw in the bulkhead.
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Last edited by PMcIntire; 07-10-2009 at 01:04 AM.
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Old 07-11-2009, 12:35 AM
  #9  
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Another update for today, the fuselage now has a tail section! Next up will be braces for the bent section of the tail, and the other side of the cockpit + more bulkheads.

BTW, I am changing the thread title by removing Orion... It's not an orion. I am using the incorrect side window style. I am using an older style. Oh well...

Actually, it is more like an MXT-t-180 Star Rocket.
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Last edited by PMcIntire; 07-11-2009 at 04:38 AM.
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Old 07-21-2009, 04:26 AM
  #10  
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And here's the latest:

Finished the other side of the model, access hatch is complete, some of forward sheeting is done, now I need more plywood to replace the temporary braces supporting the snout of the model.

I've run some more predictions on motocalc... seems like it will be a fine flying plane. Not sure what prop I want, but if I wanted to kick it up to a 14 x 10 prop, I would be pulling around 32 amps WOT, ~350 watts, 3.5 lbs static thrust and a pitch speed of ~54 mph. Just right. A bit more power with a parallel pack setup. Cruising at half throttle, it can fly for nearly 30 minutes (4s1p), and nearly double that with a 4s2p setup. Got to break out the fish scale and ammeter for reality.
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Old 07-26-2009, 01:38 AM
  #11  
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Candy arrived in the mail today...

4S1P or 4S2P for in flight... extra cells are for other models. Got a great deal for them at battlepacks. They're much lighter than I expected, and after testing the voltages, the largest deviation I saw was by 3/1000 of a volt. Most are within 1/1000 of a volt of each other. Very high construction tolerances I'm sure. These are the same cells used in the Tesla Roadster. The shrink covering is very pretty, like a fluorescent chartreuse pearl.
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Old 05-13-2010, 03:06 AM
  #12  
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The cells have since been soldered together. One note of advice if soldering A123's together, use a powerful soldering iron, and get aluminum flux for the oddball side if the cell. Soldering job worked on that end, but it isn't gorgeous looking. Other side looked normal.

And I wont get by without posting some progress pictures. I have since built up an elevator for the model, I've broken apart the temporary spacers in the inboard wing panels, and brass/copper (of that general type) tubes are curing in a mix of epoxy and microballoons at the inboard wing panels.

I now have I believe 3 1/2 or 4" trexler balloon wheels for this plane too. Wahoo it's going to be a bush plane!
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Old 05-13-2010, 03:32 AM
  #13  
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real nice looking plane. You make me want to go cut up some balsa too!

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Old 05-16-2010, 04:10 AM
  #14  
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I will be tearing out the balsa where the wing mates the the fuselage (on the fuselage). It's simply too weak for the stresses that it will undergo in flight, I'll be changing it out to basswood, spruce, something much stronger than balsa. The weakest link is like gluing 4, 1/4" square balsa endgrain to four points on the wing of a 40 size model and calling the wing mount good. You'll see what I mean in the picture. At least I got the general shape down.
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Old 09-28-2010, 11:15 AM
  #15  
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One of the few Maule builds on the net while it's a good looking plane. How is the progress?


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Old 11-30-2010, 07:10 PM
  #16  
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Progress is slow, haven't been too busy of late, just need to get at it. I finished all the major parts, so it's now a sorta-almost-ready-to-cover model. I'm dreading figuring out how I'll fix the wing mount (probably need fiberglassing... egh) and the nose section (fiberglass again). I guess it's time to man up.
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Old 11-30-2010, 09:39 PM
  #17  
road king 97
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Get some cloth and credit cards or plastic and start getting it layed down ,just not thick . looks great iam sighned up . joe
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Old 12-01-2010, 06:28 PM
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subscribed! will you be posting pdf plans here so we can enjoy your drafting labor for free?
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Old 12-08-2010, 08:41 PM
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I applaud you for all of your work on this exciting plane. As a young pilot I met and flew the M5 with Mr Maule when the factory was located in Moultre GA. It was a pre Turbo model. but still a great plane to fly. I am now retired and into building RC. Working on a P51 now, but would love to build this exciting Maule. If the plans are still available, I would love to have a set. My Email is "[email protected]". I now reside in Indianapolis.
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Old 12-12-2010, 08:24 AM
  #20  
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(Saturday)
Tomorrow I'll be building a balsa stripper for the nose section of the fuselage. I hope. I'll layer the strips in and microbaloon/fiberglass/bondo the gaps.

(Sunday)
I've bought the parts to make a threaded rod adjustable balsa cutter. I'll post pictures of that, I think if I have the energy I could have it working by noon, Monday PST.

Last edited by PMcIntire; 12-13-2010 at 09:09 AM.
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Old 12-29-2010, 08:57 PM
  #21  
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If i am planking a part that is going to get glassed i fill in the holes with light drywall compound then sand to shape and then glass . It sands easy and is light ,glassing does not mind going over it.. joe
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Old 02-22-2011, 05:27 PM
  #22  
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Got around the finishing my balsa stripper. Not the most refined looking device as of yet, but it is very functional, and a fair bit more fine tunable than I think I needed it to be.
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Old 03-03-2011, 01:50 AM
  #23  
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I like your progress. I drew up some plans a couple of years ago but never got around to building it. PM Sent.
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Old 01-03-2016, 09:29 PM
  #24  
crodrigues
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Default Maule

Hi, I would like to build this Maule RC plane.

Can you send me the plans for it?
Thanks a lot.

cdotrodrigues<at>netcabo.pt

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Old 01-05-2016, 01:23 AM
  #25  
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I will try to send a copy, have to locate the file. Or rescan
Originally Posted by crodrigues View Post
Hi, I would like to build this Maule RC plane.

Can you send me the plans for it?
Thanks a lot.

cdotrodrigues<at>netcabo.pt

Carlos
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