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ZBAG, a respectful question: a modest answer
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Terry Phillips



Joined: 11 Jan 2006
Posts: 346
Location: Corvallis, MT

PostPosted: Tue Jun 16, 2009 5:18 pm    Post subject: ZBAG, a respectful question: a modest answer Reply with quote

Interesting question, Kevin

Since we have ample evidence that flutter does occur in real CH601XL's in
flight, I guess that your question translates to,

"What evidence would it take to prove to me that the pilots who have
experienced flutter in the 601XL were lying or mistaken?"

Gosh, I don't know. All of the pilots who reported flutter were more
experienced than I am. One had thousands of hours. I find their reports
convincing. I have no reason to believe that they were lying. One person
who reported flutter in the 601XL tests was Mathieu Heintz (look up his Sun
n Fun AvWeb podcast). I guess that I would have to conclude that Mathieu is
either incompetent or dishonest. I am not ready to make that conclusion. We
have at least two second hand reports of flutter in 601XL from Chris Heintz
(look through Chris's letters to owners). I would have to conclude that
Chris was wrong in his letter.

Here's what I think I know. If the balance on an aileron satisfies the
criteria in A&E Report 45, then my understanding is that the FAA is willing
to forego flutter testing for certificated airplanes. That's simple enough
for me. Add about 5 lbs or so to each wing in a well designed
counterbalance, and according to established criteria, aileron flutter will
not happen. If you look at Fig. 24 of Prof. Weltin's GVT report, you'll
see a pretty reasonable design for a 601XL aileron counterbalance. I
suspect that Zenair has a better drawing of that somewhere. It looks good
to me.

Hey, E-AB aircraft builders can do whatever they want to their airplanes.
If you do not believe that flutter is a problem, Kevin, then don't add
counterbalances. It would be most revealing if half the fleet added the
counterbalances, plus the LAA mods, whatever they work out to be, and half
the fleet flew 601XL's made exactly to the prints. Then in a couple of
years we would find out whether the counterbalances, et al, made a
difference--or not. So those of you who have absolute faith in the design,
you can be the control group. Others, whose faith is not so solid can make
the mods they find appropriate. A couple of years of flying should tell the
tale. I cannot understand why anyone with absolute faith in the design
would feel threatened by the mods that others make to their planes. If you
are right, you can have the last laugh at those of us who lack your
absolute faith. For sure, the last thing I would want to do is to impose my
own personal concerns on you.

So, I suggest that everyone tone down their rhetoric. Then make the mods to
your airplane that makes sense to you, or not, and in a couple of years we
should have the answer. I've got a pretty good idea what I will do. How
about you, Kevin?

Terry
At 06:03 AM 6/16/2009 -0700, you wrote:
Quote:
My question is directed to anyone who has design questions regarding the
601XL.

What evidence would it take to prove to you the 601XL is free of flutter?

Regards,
Kevin Kinney


Terry Phillips ZBAGer
ttp44~at~rkymtn.net
Corvallis MT
601XL/Jab 3300 s .. l .. o .. o .. w build kit - Tail, flaps, & ailerons
are done; waiting on the wings
http://www.mykitlog.com/N47TP/


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rtdin



Joined: 16 Mar 2008
Posts: 46
Location: Florida panhandle

PostPosted: Tue Jun 16, 2009 9:17 pm    Post subject: ZBAG, a respectful question: a modest answer Reply with quote

I so wanted to stay out of this, however I cannot stand by and allow a few who don't know me to imply that because I am a member of ZBAG, I would like to kill off the 601XL. Doesn't pass the sniff test. I have a big investment in time and money in my project. It's on hold for the present. My grand kids will not be allowed in it until a few things get ironed out.

As Rick says, "Pilots that only fly FAR 23 A/C have trouble with LSAs." I guess I may have some trouble despite owning a Champ and Luscombe. Despite having many hours in FAR 23, 27, 29, CAR 3 and a couple of E-AB A/C, including a 601XL, I guess I don't have a chance. My first thought is if this is the horse that can't be rode and it has known bad traits, Why put low timers in it? Can't these quirks be fixed? I used to instruct in helos and sailplanes and I cannot trust an aircraft that will scare a low time pilot. I have faith that the LAA will civilize the 601XL.

I bet that most of the ZBAG haters have only gone on the site to use their flame throwers. Its a shame that they don't take some time to go through the stuff in the "Files" section. That stuff is available to everybody and may even be educational.

Terry has some good points about control balancing. Its hard to find anything flying that doesn't use mass balance. It is that accepted world wide. See Zenair Newsletters 40 and 41 for a Zenith design. Most small planes use 1.5 to 2 LB per wing. The Sonex uses 5LB and is trouble free.

If there were no accidents with the 601XL, we would not be having this conversation and I would have my project finished.

Bob Dingley
601XL (holding at the wings)




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kkinney



Joined: 11 Jan 2006
Posts: 42

PostPosted: Wed Jun 17, 2009 4:36 am    Post subject: Re: ZBAG, a respectful question: a modest answer Reply with quote

> How about you, Kevin?

I freely admit I know far less that everyone else seems to and I apologize for answering a question with a question. But what I do depends on the answer to that question.

Have there been any suspect accidents on aircraft with flex hinges?

Regards,
kk


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PostPosted: Wed Jun 17, 2009 5:11 am    Post subject: ZBAG, a respectful question: a modest answer Reply with quote

The only actual aileron flutter that I have read about with the XL is those
who reported it, slowed down to stop it, and post flight found that their
cables were slack. The also reported that after tightening the cables, the
flutter went away.

In the one report of "wing flutter", over the turbulent rising air mass of
a powerplant, the pilot stated he DOVE down any away to stop the
"flutter"!!!!!!!!!!!!!!!??????--try increasing airspeed with real flutter
and see what happens.

Also, what some overlook is:
See Page 6 of the NTSB Report where they report as part of Zenith's
Certification, Zenith did IN FLIGHT FLUTTER TESTING of the XL.

Tony Graziano
XL/Jab; N493TG, 502 hrs.

---


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Gig Giacona



Joined: 10 Jan 2006
Posts: 1416
Location: El Dorado Arkansas USA

PostPosted: Wed Jun 17, 2009 5:49 am    Post subject: Re: ZBAG, a respectful question: a modest answer Reply with quote

rtdin wrote:
I used to instruct in helos and sailplanes and I cannot trust an aircraft that will scare a low time pilot.


If you instructed in helicopters then I'm sure you are familiar with SFAR74 and the issues with the Robinson R22& R44 that caused it. We may well have a similar though much less pervasive with the 601XL where additional training is needed.

The issues that Rick raised were not 601XL specific but were about the new LSAs in general and were put forth by the insurance companies when they saw a correlation between high time pilots having trouble with the light and responsive LSA aircraft that they started flying with little or no transition training.


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jmaynard



Joined: 27 Feb 2008
Posts: 394
Location: Fairmont, MN (FRM)

PostPosted: Wed Jun 17, 2009 6:10 am    Post subject: ZBAG, a respectful question: a modest answer Reply with quote

On Wed, Jun 17, 2009 at 06:49:16AM -0700, Gig Giacona wrote:
Quote:
The issues that Rick raised were not 601XL specific but were about the new
LSAs in general and were put forth by the insurance companies when they
saw a correlation between high time pilots having trouble with the light
and responsive LSA aircraft that they started flying with little or no
transition training.

I haven't actually done any instruction for real (seems there's a lack of
demand), but I have had a few other pilots fly my airplane with me aboard
now. I know that it took me a while to get used to the sensitive elevator. I
make a point of telling other pilots who fly with me that the elevator is
sensitive (and the pitch trim even more so), and give them a chance to try
it up in the air while I'm ready to intervene if things get too crazy.

I had one guy just about to take his private check ride aboard one time. I
let him do the takeoff; I told him to lift off at 60 KIAS, then lower the
nose and fly away at 70, accelerating to 80 once at 500 AGL. (I've found
this to work well in getting the best climb performance. Vx at 57 KIAS?
Yeah, right.) He was a bit too aggressive in lowering the nose, and I
quickly grabbed the stick before we found ourselves hitting nose first. He
was quite surprised by the pitch sensitivity; in retrospect, I should have
explained what was going to happen before then (and have done so with other
pilots since).

This only applies to the elevator, BTW; other pilots have said that the
ailerons and rudder are much heavier in feel, and took no real adjustment.

Yes, transitioning into the Zodiac takes some dual. I'm not sure 5 hours is
warranted for every pilot, but that seems to be the industry standard. Is
this an explanation for problems we've seen? Possibly. Is it *the*
explanation? That very much remains to be proven.
--
Jay Maynard, K5ZC, PP-ASEL, CFI-SP http://www.conmicro.com
http://jmaynard.livejournal.com http://www.tronguy.net
Fairmont, MN (KFRM) (Yes, that's me!)
AMD Zodiac CH601XLi N55ZC http://www.tronguy.net/N55ZC.shtml


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PostPosted: Wed Jun 17, 2009 6:11 am    Post subject: ZBAG, a respectful question: a modest answer Reply with quote

Hi, Bob. Rick here.

Quote:
As Rick says, "Pilots that only fly FAR 23 A/C have trouble with LSAs." I
guess I may have some trouble despite owning a Champ and Luscombe. Despite
having many hours in FAR 23, 27, 29, CAR 3 and a couple of E-AB A/C, including
a 601XL, I guess I don't have a chance. My first thought is if this is the
horse that can't be rode and it has known bad traits, Why put low timers in
it? Can't these quirks be fixed? I used to instruct in helos and sailplanes
and I cannot trust an aircraft that will scare a low time pilot. I have
faith that the LAA will civilize the 601XL.

Please don't misquote me, or attribute meanings to my posts that were never intended.

What I said was there is a disturbing uptick of accidents in LSAs with experienced pilots who fly them like the Part 23 aircraft they are used to. I DID NOT say "Pilots that only fly FAR 23 A/C have trouble with LSAs" as you posted. What I said, in a nutshell, was that pilots who expect the same weather capability from an LSA compliant design frequently have unpleasant surprises, and this is NOT specific to the 601 airframe. I've found the 601XL very easy to fly, takes off slow, lands slow, and is very docile in the air. The closest I could get to a stall was a mush. But with an empty weight of only 800 pounds or so and light wing loading, it's going to respond to every bump or patch of rough air, and tell you about it.

With your myriad flying experience, I would be very surprised if you had any problems at all with the 601. And it's interesting that low time pilots don't seem to have a problem with the 601 at all.

I choose my words carefully, and I resent others twisting them to derive meanings never intended.

Rick Lindstrom
N42KKP


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PostPosted: Wed Jun 17, 2009 6:49 am    Post subject: ZBAG, a respectful question: a modest answer Reply with quote

Quite possible, although at present it's just another idea. Do have any
ideas on what might be done or has Zenith identified it as an issue? Can you
think of any small change to the existing design that would mitigate the
problem if it exists?

These are the types of discussions we SHOULD be having.

---


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Gig Giacona



Joined: 10 Jan 2006
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Location: El Dorado Arkansas USA

PostPosted: Wed Jun 17, 2009 7:07 am    Post subject: Re: ZBAG, a respectful question: a modest answer Reply with quote

d.goddard(at)ns.sympatico wrote:
Quite possible, although at present it's just another idea. Do have any
ideas on what might be done or has Zenith identified it as an issue? Can you
think of any small change to the existing design that would mitigate the
problem if it exists?

These are the types of discussions we SHOULD be having.

---


Agreed it is exactly the type of discussion. But the fix for this issue isn't a design change it is a training issue.

To support this I put forth the theory that the reason that none of the accident aircraft that have suffered airframe failure were flown by pilots that flew the airplane during its' 25-40 phase 1 period. The first part of which a pilot would presumably be taking extra care in maneuvering the aircraft and learning its characteristics.

Let's assume for a second that the minimum a design change to mitigate a light elevator is going to cost is $1000/plane. (Nothing in a plane costs less than that.) That will buy you a minimum of 20 hours of CFI time. And that 20 hours will do more to assure your future safety than any design change ever would. That is not to say I think it takes 20 hours. 5 should do it and will make insurance companies happy.


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PostPosted: Wed Jun 17, 2009 8:25 am    Post subject: ZBAG, a respectful question: a modest answer Reply with quote

If Zenith feels that extra training to overcome the issue is appropriate and
issues an advisory to the effect then maybe that is enough. I expect it
would only make things worse as it would create the illusion of an aircraft
that is difficult to fly and I don't think that's true. So far Zenith has
chosen to address it with a required design modification in the form of
elevator stops if I understand things correctly.

A design change to actually alter the stick forces is only an idea, as yet
unproved, unapproved and not required. In fact I would not like to see one
required, but if there is an issue that a change could address in a similar
fashion to the not required balanced ailerons I think it would be worthwhile
to explore it as an option. It's always nice to have options.

Zenith will not require changes from their builders without substantial
proof that there actually IS an issue and a need. So far they have
addressed the issue with elevator stops, REQUIRED I think. I don't think
ZBAG had anything to do with that requirement it was due to the sensitive
pitch aspect of the design and the accidents.

So which approach do you think is better in the long run, training to
address a particular and possibly unusual aspect of the airframe or an
option to bring the aircraft more in line with normal practice. I'd be happy
with both.

Quote:


Agreed it is exactly the type of discussion. But the fix for this issue
isn't a design change it is a training issue.

To support this I put forth the theory that the reason that none of the
accident aircraft that have suffered airframe failure were flown by pilots
that flew the airplane during its' 25-40 phase 1 period. The first part of
which a pilot would presumably be taking extra care in maneuvering the
aircraft and learning its characteristics.



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Gig Giacona



Joined: 10 Jan 2006
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Location: El Dorado Arkansas USA

PostPosted: Wed Jun 17, 2009 8:58 am    Post subject: Re: ZBAG, a respectful question: a modest answer Reply with quote

The elevator stops don't effect the issue brought up by the NTSB where the elevator has less resistance as Gs increase. They just reduce the amount of down elevator you have available. A design change to change that would probably be complex and expensive. (Especially for the S-LSA planes.) Though I have yet to see anyone who flies a 601XL confirm this condition actually exists to a point where they don't feel they can control the aircraft.

I'd be willing to bet that somewhere on the Zenith site it already suggests that a pilot get transition training before flying any of their planes. That is the sort of CYA stuff companies love.

Training is never a bad thing. Pilot certificates all the way up through ATP are a license to learn. The FAA knows this and is why they have developed the Wings Program and have set up the Flight Review requirements the way they have.The insurance companies know it and are starting to require transition training.

SFAR 74 that was developed for the Robinson R22 & R44 and took a couple of years to develop. That SFAR requires specific training and log book entries for every pilot that flies those helicopters no matter if it is zero hour student or an pilot that is transitioning from 3000 hours in an Apache.
d.goddard(at)ns.sympatico wrote:
If Zenith feels that extra training to overcome the issue is appropriate and
issues an advisory to the effect then maybe that is enough. I expect it
would only make things worse as it would create the illusion of an aircraft
that is difficult to fly and I don't think that's true. So far Zenith has
chosen to address it with a required design modification in the form of
elevator stops if I understand things correctly.

A design change to actually alter the stick forces is only an idea, as yet
unproved, unapproved and not required. In fact I would not like to see one
required, but if there is an issue that a change could address in a similar
fashion to the not required balanced ailerons I think it would be worthwhile
to explore it as an option. It's always nice to have options.

Zenith will not require changes from their builders without substantial
proof that there actually IS an issue and a need. So far they have
addressed the issue with elevator stops, REQUIRED I think. I don't think
ZBAG had anything to do with that requirement it was due to the sensitive
pitch aspect of the design and the accidents.

So which approach do you think is better in the long run, training to
address a particular and possibly unusual aspect of the airframe or an
option to bring the aircraft more in line with normal practice. I'd be happy
with both.



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PostPosted: Wed Jun 17, 2009 9:29 am    Post subject: ZBAG, a respectful question: a modest answer Reply with quote

No the stops do not affect the forces, they stop a pilot from inadvertantly
applying too much elevator as a consequence of the decreasing force. That's
certainly one way to go, and by far the easiest and least expensive. Do you
have an objection to an optional change that addresses the issue in a
different way? I have no idea what it would cost as the option doesn't
exist, I'm not sure we could simply assume it would be expensive or
complicated, we could likely assume it would not be required as a retrofit.

---


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Scotsman



Joined: 27 Aug 2007
Posts: 89
Location: Johannesburg, South Africa

PostPosted: Wed Jun 17, 2009 10:19 am    Post subject: Re: ZBAG, a respectful question: a modest answer Reply with quote

Just a quick question.....

Is there a simpler "fix" for the pitch sensitivity whereby lengthening the lower and upper elevator horn would reduce the degrees of deflection per cm that the stick is moved in pitch? Is there sufficient space in the rear of the fuselage to accommodate this?

If possible this would be cheap alternative. Any thoughts anyone?

James


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Terry Phillips



Joined: 11 Jan 2006
Posts: 346
Location: Corvallis, MT

PostPosted: Wed Jun 17, 2009 10:39 am    Post subject: ZBAG, a respectful question: a modest answer Reply with quote

Yep, that's the way I see it also. Tight cables, no flutter. Loose cables,
yes flutter.

Relying on tight cables to prevent flutter does not meet FAA standards for
certificated airplanes. But we're mostly talking E-AB aircraft here, and
E-AB aircraft do not have to meet FAA standards. So, if you are happy with
relying on tight cables to prevent flutter in your E-AB 601XL, then that is
the way you should go. Or, if you think that, just maybe, the FAA has good
reasons for not relying on tight cables to prevent flutter, then you might
want to take additional steps.

I've tried to transcribe part of Mathieu Heintz AvWeb Podcast. What I hear is:

Quote:
"the latest thing they've just completed now is a series of flutter tests
in a wind tunnel"

"What we see from there is very clearly that when we have tight control
cables per design requirements, that we do not have a flutter problem with
the airplane. When you loosen up the cables, sure enough we get some
flutter. It's not flutter in the sense that it's going to rip a wing
apart, but it's enough to scare a pilot. Then when we put a mass balance
weight with the loose control cables, then sure enough that goes away."

So, it seems that the 601XL wing is prone to flutter with loose cables, and
that aileron counterbalance will prevent 601XL aileron flutter, even with
loose cables. The choice is yours.

Terry
At 08:10 AM 6/17/2009 -0500, you wrote:
[quote]

The only actual aileron flutter that I have read about with the XL is
those who reported it, slowed down to stop it, and post flight found that
their cables were slack. The also reported that after tightening the
cables, the flutter went away.

In the one report of "wing flutter", over the turbulent rising air mass
of a powerplant, the pilot stated he DOVE down any away to stop the
"flutter"!!!!!!!!!!!!!!!??????--try increasing airspeed with real flutter
and see what happens.

Also, what some overlook is:
See Page 6 of the NTSB Report where they report as part of Zenith's
Certification, Zenith did IN FLIGHT FLUTTER TESTING of the XL.

Tony Graziano
XL/Jab; N493TG, 502 hrs.

---


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Gig Giacona



Joined: 10 Jan 2006
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Location: El Dorado Arkansas USA

PostPosted: Wed Jun 17, 2009 10:55 am    Post subject: Re: ZBAG, a respectful question: a modest answer Reply with quote

I can't think of a simple or cost effective way to modify the design that would address this issue. I have no doubt that someone could design a complex system of weights and/or pulleys that would do it but complex isn't why I decided to build a 601XL and I'm not that hot for a complex change for a problem that shouldn't even show itself except at the edges of the flight envelope and can be trained around.

As far as changing the length of the upper and lower elevator horns you then get into the issue that there isn't enough room in the cockpit for the stick to move all the way.
d.goddard(at)ns.sympatico wrote:
No the stops do not affect the forces, they stop a pilot from inadvertantly
applying too much elevator as a consequence of the decreasing force. That's
certainly one way to go, and by far the easiest and least expensive. Do you
have an objection to an optional change that addresses the issue in a
different way? I have no idea what it would cost as the option doesn't
exist, I'm not sure we could simply assume it would be expensive or
complicated, we could likely assume it would not be required as a retrofit.

---


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PostPosted: Wed Jun 17, 2009 11:19 am    Post subject: ZBAG, a respectful question: a modest answer Reply with quote

It would appear from what I have read that cables have to be very loose
(slack) such as the stick can be moved without initial movement of the
ailerons. A preflight check and a "check controls are free and proper"
before flight check should, I believe, detect improper (slack) cable
tension.

Tony Graziano
XL/Jab: N493TG; 502 hrs

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kkinney



Joined: 11 Jan 2006
Posts: 42

PostPosted: Wed Jun 17, 2009 11:21 am    Post subject: Re: ZBAG, a respectful question: a modest answer Reply with quote

Scotsman wrote:

Is there a simpler "fix" for the pitch sensitivity whereby lengthening the lower and upper elevator horn would reduce the degrees of deflection per cm that the stick is moved in pitch?


Of the top of my head, I'd say there isn't much room to spare. It would seem to alter more flight characteristics than just pitch sensitivity, such as reducing max elevator deflection.

Assuming you have the original single stick, reducing sensitivity could be accomplished by adding a friction plate where the stick attaches at the torque tube. That would accomplish the single goal of reducing pitch sensitivity. I'm not an aero-engineer, so I can not say what else may be affected.

This could be something to ask the factory.

Regards,
Kevin Kinney


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d.goddard(at)ns.sympatico
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PostPosted: Wed Jun 17, 2009 12:10 pm    Post subject: ZBAG, a respectful question: a modest answer Reply with quote

I can't think of one either, but I could not have conceived a way to do away
with aileron cables and install push/pull tubes and that's been done. It
also looked fairly straightforward and easy to do while building. It's a
good reason to try to run these questions past a group of peers and see who
might have an idea. There's no reason to simply dismiss the notion as
complex or expensive when it doesn't exist. If a system is devised, I have
extreme doubts that anyone would be required to install it. It would simply
be an option for those who want it, do you object?
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n801bh(at)netzero.com
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PostPosted: Wed Jun 17, 2009 12:39 pm    Post subject: ZBAG, a respectful question: a modest answer Reply with quote

Ok. I am getting confused again <GG> Mathieu said >"the latest thing they've just completed now is a series of flutter tests
Quote:
in a wind tunnel.
Is the GVT considered a wind tunnel test or was there two seperate tests performed ??

do not archive
Ben Haas
N801BH
www.haaspowerair.com

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Terry Phillips



Joined: 11 Jan 2006
Posts: 346
Location: Corvallis, MT

PostPosted: Wed Jun 17, 2009 8:49 pm    Post subject: ZBAG, a respectful question: a modest answer Reply with quote

Apparently, the tests for the DAeC included several components
  • ground vibration tests (GVT)
  • Load tests, probably to German microlight MTOW of 472 kg.
  • According to Mat's Podcast, some sort of wind tunnel tests. It would be nice if Zenair would post a report for the wind tunnel tests.
The video that Zenair posted of the GVT on the 650 shows something of what those tests entailed. See

http://www.youtube.com/watch?v=0VMMVuVrweM

The wind tunnel tests would be an entirely separate affair. To date I have not seen any report of the wind tunnel tests nor of the load tests.

Terry

At 08:36 PM 6/17/2009 +0000, you wrote:

[quote]Ok. I am getting confused again <GG> Mathieu said >"the latest thing they've just completed now is a series of flutter tests
>in a wind tunnel.

Is the GVT considered a wind tunnel test or was there two seperate tests performed ??

do not archive


Ben Haas
N801BH
www.haaspowerair.com

--------


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Terry Phillips
Corvallis, MT
ttp44<at>rkymtn.net
Zenith 601XL/Jab 3300 slow build kit - Tail feathers done; working on the wings.
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