Modular Fuselage Structure FD1-1U Nose and Tail Fairing

General Information

This model contains components to assemble nose and tail fairings for an R/C aircraft.  These components use a common bulkhead to which nose and tail shapes can be adapted.  You will need to bond the pieces together using a glue such as CA at the joint surfaces.  The initially provided nose assembly is a volume optimized shape that should provide reasonably good aerodynamic efficiency while allowing for a large flat plate aperture at the nose for adaptation of FPV cameras, motor shafts, or other nose mounted components.  The tail assembly accommodates an offset tailboom and balances between aerodynamic efficiency, weight, and durability.

These are part of a system for constructing fuselages and other aerodynamic bodies.  Additional components, such as nose and tail fairings, wing attachment structures, etc will be provided in separate models and linked.  The figure below is an exploded view of components of this system.

These components use a 100 mm bulkhead width, which is the baseline 1U unit size in the FD1 system.  The nose and tail fairings are common to all panel thicknesses used in the central frame assemblies.  Other unit sizes will be published as well.

All components were designed using python scripting and OpenSCAD modeling, allowing parametric design of many permutations of unit size and panel thickness.  Additional information and source code will be linked here as they are published.

The 1U frame section uses 4 mm circular cross section longerons, typically using pultruded carbon tube or rod.  Wall thickness of the longeron (if using tube) can be varied based on the strength needs of the specific application.

The 1U Fuselage Unit:

Bulkhead Cross Section Dimensions

The outer perimeter, longeron holes, and fastener holes of the bulkhead cross section for the 1U unit size bulkheads conform to the dimensions shown in the diagram below:

Detailed Component Descriptions

bulkhead_cowling_bolt

This is a cowl bulkhead design option with holes for a 4 mm fastener inboard of the longerons.

bulkhead_cowling_anchor

This is a cowl bulkhead design option with holes for a heat press threaded insert for a 4 mm bolt inboard of the longerons.

nose_cowl

This is a thin shell cowling shape that is part of the nose cowl assembly.  It should be printed with zero infill and no top or bottom thickness.

nose_nose

A transition piece between the nose cowl and the flat nose plate.  Print this with at least 2 perimeters.

nose_plate

A flat section plate that can be modified for nose mounted equipment such as cameras, motor shafts, or other nose mounted components.

tail

This is a thin shell cowling shape that is part of the tail assembly.  It should be printed with zero infill and no top or bottom thickness.

nose_assembly_tool

This is an alignment tool to assist alignment and bonding of the nose_nose to the nose_cowl.

Nose Assembly

The components of the nose are shown below:

Apply a mold release such as paste wax or a thin layer of vaseline to the interior of the nose assembly tool.  Note: ensure the mold release will not contaminate the joint between the "nose_nose" piece and the "nose_plate" piece.

Insert the nose_nose piece into the alignment tool

Then insert the nose_cowl piece onto it. 

The cowl bulkhead can be used to add rigidity to the nose cowl during this step.  Ensure the cowl and nose are well seated and aligned in the tool.  Apply medium CA in several locations around the perimeter of the nose_nose to nose_cowl to the bond between the cowl, but do not flood the joint.  We want to ensure we do not bond the pieces to the alignment too.  Use kicker to cure the CA quickly, then remove from the tool.  Once removed from the tool, apply CA to the remainder of the glue line. Any CA that leaks through the glue joint can be sanded flush with the cowl surface.

Bond apply CA either to outside of the bulkhead flange or to the interior edge of the cowl and assemble the two together.  The alignment tool makes for a good stand for the nose during this step.  Ensure the entire perimeter of the cowl is seated onto the bulkhead flange before the CA cures.

Apply CA to the nose plate and bond it in place from the inside.  The nose assembly is complete.

Tail Assembly

To assemble the tail, apply CA to the bulkhead exterior flange or cowl interior edge and assemble them together in the same way as the nose cowl assembly.

Printing Recommendations

All components are designed to print in the orientation provided.  Bulkheads and the Nose Plate are designed to print typically with 100% infill and multiple perimeters for strength.  The nose and tail cowls are designed to print in vase mode or 0% infill.  Note that the bulkhead cowl is designed assuming a single perimeter thickness where the cowl bonds to its flange.

The Modular R/C Aircraft Collection

This collection is a set of models for R/C aircraft that I have designed to be generally interoperable and support design and fabrication of a wide range of aircraft configurations:

https://www.printables.com/@Uenbzsto/collections/2458682

Related FD1 Models

These models are part of the FD1 fuselage structure system.

Support This Project

If you liked this model, please consider buying me a coffee!

 Buy me a coffee