Backcountry Pilot • FankenmegasmallMaule

FankenmegasmallMaule

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FankenmegasmallMaule

I have most all the parts to start on a Experimental Maule kinda project.
Rebuilt sort of M4 fusalage, with changes, have 2 sets, M4 wings, thinking about extending flaps, moving the ailerons out by adding a piece of spar and a couple of ribs, with a funny wingtip. Building it like a PA12 with nice comfy single seat in the front with a side by side in the back, as in a couple of SC seats. Double doors on both sides in the back and just 1 in the front, swing up seaplane type?? Stick in the front.
Have very good high HP220 Franklin to make it go.Ported and polished,flow matched, electronic fuel injection and ignition. Maybe a set of those slats that guy in Montana makes to put on the wings.
VG's from Australia, and some of those new long legged gear that Hotrod is pedaling with some 35"s or an old set of Schnieder slicks that I have come across.
Any one have any good advice, I will even take the other kind!!
This is not a start tomorrow project but am getting all the parts in one spot before I start it.
Spose I could make it a biplane, I have enough parts????Hmmm? :mrgreen:
GT
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Re: FankenmegasmallMaule

Hey George
Why not call the Big Rocks long props guy. Lonnie??? I'm sure he has been all through this. I emailed him with the same thought and he was quick to reply.
I think it's a great idea and a lotta fun when done.
Good luck
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Re: FankenmegasmallMaule

You're thinking of Greg AKA mauleguy.
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Re: FankenmegasmallMaule

Have talked to Greg a bit, he did'nt think much of my wing extension idea!!
GT
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Re: FankenmegasmallMaule

Hey George,

IMHO: Pay attention to the wingtips on the Dornier series of single and twin aircraft, and the wingtips on just about any high performance sailplane designed in the last 25 years (Discus, LS-6, etc.) While you're at it, look at the shape of the wingtips on just about any raptor and bird. Straight or slightly swept back trailing edge, sharply swept or curved leading edge.

Mount the tip with about 5 degrees of dihedral angle between the main wing panel and this tip (plus whatever dihedral is at the root ends of the wing) , which is technically correctly textbookly referred to as polyhedral. This will "throw" the vortex out a few inches further, increasing effective span... BTW this is a completely different effect than the reason why polyhedral is used on model gliders.

If you are up for the engineering and fabrication challenge, put in the "crow" configuration setting, flaps down 45-50 degrees and ailerons up about 5 or 8 degrees, for the final landing flap position. That will give you the best combination of low speed control, safety, and steep approach with no float on flare-out.

Bottle of single-malt says you will be happy you took this advice.
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Re: FankenmegasmallMaule

EZ, Just the opposite of the Robertson? Is that what I hear? Sounds interesting, might have to have your personal Phone # before I get done!!
I know on my old J5, it sure did make a big difference if the aileron's were set, up, even, or down 3/4 of an inch!!
Thanks GT
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Re: FankenmegasmallMaule

M6RV6 wrote:EZ, Just the opposite of the Robertson? Is that what I hear? Sounds interesting, might have to have your personal Phone # before I get done!!
I know on my old J5, it sure did make a big difference if the aileron's were set, up, even, or down 3/4 of an inch!!
Thanks GT


Yes, opposite of Robertson for a reason. Drooping the ailerons downward with the flaps makes more camber across the whole wing, thus maximum lift. No argument about that. But it also means there is a greater risk of tip stall in gusty conditions, where you have the wing making a lot of lift all the way to the tips. If you were flying in smooth air the drooped ailerons would give you the slowest flight possible. But as those 20K hour graybeards in AK will tell you, slowest flight does not always equate to best achieved short field performance. For reliable, safe, predictable short landing required full control and real-world maneuverability down near the stall. And you need lots of drag for the steepest approach without building up speed.

I have no experience with the Robertson mod. It is certified and that means they proved it is safe. But they might have done a lot of other things to achieve that when the ailerons were drooped. And the Robertson ailerons are not drooped as far as the flaps.

What I can say with a little experience behind me is that the "crow" system works, works very well, and adds another level of safety/control/drag. Having t6he ailerons a little bit up, with the flaps a lot down, does several good things on landing. First, it reduces the camber at the wingtip, and greatly increases the effective twist (washout). This reduces or even eliminates tip stalls from gusts, harsh maneuvering at low speed, etc. Chalk up one on the safety side.

The washout lowering the AOA at the tip means that the air flowing over the top of the wingtips remains attached, with a thinner boundary layer. So your ailerons are still very powerful even at low speeds. no mushy softness. Raising the ailerons and making the wing act like it is twisted (like a propeller) crates a lot of drag, giving you a very steep descent but without the speed buildup.

Raising the ailerons in SOME cases will give you back enough otherwise lost control authority and safety, so you can use a larger deflection on the flaps. Large flap deflections can easily "blank out" the tail. So there is some maximum flap deflection, but this is limited by tail blanking and not tip stalls or control authority.

So although I can't say from experience, I would guess that a Franken-Maule with full span drooping flaps and ailerons would be able to fly a tad slower, but that a Franken-Maule with flaps down and ailerons up would be able to make steeper approaches, over trees and hills,and fly slowly in gusty conditions with more control, and have an extra margin of safety against tip stalls.

Now this means you will have an incredible handling airplane for steep short landings, but for short takeoff there is a downside to this, which is that you have a lot more drag than lift. So for takeoff you would want to have mild or moderate flap deflection, matched with just a little LESS droop on the ailerons (like Robertson). That would give you the best climb for the available power, with the least drag.

It's not me you want to talk to on the phone, it's a German guy named Dipl. Ing. Gerhard Waibel in a little Bavarian town named Poppenhausen. He perfected the "crow configuration" in 1976, on the AS-W20 sailplane that was my first love.
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Re: FankenmegasmallMaule

And Schleicher still uses it on my ASH26E and it's new replacement, the ASH31Mi (unfortunately I don't have one on order).

Besides the landing flap position EZflap describes, they also use a mixer so the flaps or "flaperons" follow the ailerons for better roll rate with the 18 to 20 meter spans they are using on these ships.
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Re: FankenmegasmallMaule

Just looked at your photo gallery Bumper, I remember contest #ZZ was a guy named Rick Anderson, had a PIK-20. Then I remembered just how long ago that was. Man, I feel old.

When you do get your new ship, I volunteer to keep your old obsolete '26 exercised and waxed for you... my generosity is strictly as a free service out of the goodness of my heart, to keep these old antique historical artifacts in working order [-o<
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Re: FankenmegasmallMaule

oops double post, sorry
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Re: FankenmegasmallMaule

Yeah, drooping the ailerons is a terrible idea, no doubt. No self respecting builder of powered aircraft would even THINK of going there.....but then there's dehavilland, whose Beaver, Otter, Twin Otter, etc droop their ailerons.....

Remember, the man is talKing orders of magnitude lower aspect ratio on his project than a sailplane.

Also, I'd talk to your local FAA before you get too far along to be sure they will certify an airplane under exp/amateur built with a LOT of certified used airplane parts in it. Bear in mind the 51% rule here. FAA has been getting VERY strict on this these days.

Good luck.

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Re: FankenmegasmallMaule

Greg probably didn't think much of the wing extension cause in his case he'd be scraping the canyon walls he flies through... :lol:
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Re: FankenmegasmallMaule

Naw, Greg already has long wings, Im just trying to make my short ones longer #-o
Steep approach with a Maule is not a problem, you cut the power and pull the yoke all the way back and you will have a 700-1000 fpm, depending on where you have the flaps. With VG.s you have all the control you need, you just have to use the rudder like your supposed to! :wink:
Would be interesting to play with the crow concept tho!!
Keep the ideas coming, looking at them all.
Mike, will be working with a DAR, seems like the FAA could care less as long as the DAR says it's OK. #-o
Thanks GT
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Re: FankenmegasmallMaule

M6RV6 wrote:, will be working with a DAR, seems like the FAA could care less as long as the DAR says it's OK. #-o
Thanks GT


True, but the regs say if you use a major component (wings, fuselage, landing gear, etc) off a certified aircraft then it must be maintained in accordance with part 43 and any work done on those parts can not be counted as parts of the 51%. So no major mods without FAA approval and you probly won't meet the 51% if you use more than 1 major component. If you know a DAR that will sign it off then go for it! Sounds like a awesome project to me. I spoke with several DARs about a project I wanted to do and none thought it would meet the 51%. That was with using stinson wings and empennage, everything else was going to be scratch built.

There is a FAA form the DAR uses to check for the 51%. I can find the number if you want.
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Re: FankenmegasmallMaule

For the experimental, it really boils down to FAA form 8000-38. There about 119 points for a non canard, non rotocraft experimental. For example, the fuselage is worth only 12 points, or 10% of the total project. It doesn't matter where the parts come from, whether an original, PMA, or experimental source as long as when you add up your points you have 51% of the 119 points.
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Re: FankenmegasmallMaule

GT,

I'm familiar with a guy who has a really neat and highly modified PA-12, which he got the FAA to allow in the experimental category without any further restrictions. For the wings, I'm told he got the spar blanks and just never cut them off--he just built the wings to the length of the blanks.

If you think it could be useful to talk to him (whether about long wings, or about converting a certified hull into an unlimited experimental), let me know and I'll try to put you in touch with him.

Sounds like a neat project! Good luck to you.
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Re: FankenmegasmallMaule

The DAR SHOULD know the drill. It's been done. As with everything associated with the FAA, however, every district is like its own little agency, often with widely varying interpretations of the regs.

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Re: FankenmegasmallMaule

[quote="EZFlap"].........
Having the ailerons a little bit up, with the flaps a lot down, does several good things on landing. First, it reduces the camber at the wingtip, and greatly increases the effective twist (washout). This reduces or even eliminates tip stalls from gusts, harsh maneuvering at low speed, etc. Chalk up one on the safety side.
The washout lowering the AOA at the tip means that the air flowing over the top of the wingtips remains attached, with a thinner boundary layer. So your ailerons are still very powerful even at low speeds. no mushy softness.......[quote]

To achieve the root-stalls-first quality, I always wondered about putting VG's just on the outboard section of the wing (in front of the ailerons). Never seen it done, but I have seen the opposite done to achieve the same result-- stall strips put on the leading edge at the root end .
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Re: FankenmegasmallMaule

I can't speak for the Beavers and Otters, as to why or how much their drooping ailerons are safe, or whether those airplanes are prone to tip stalls in gusty conditions. Obviously those airplanes are safe and have been flying for many many years. My hat's off to Sir Geoffrey and the Canadians on the project way back. But similar to Mike's comment that there is a difference in aspect ratio, there is also a big difference between weights, chord length and wing loadings (Re and all that) from a Beaver to a Maule. I have no idea if the crow configuration was being studied or practiced in aircraft design when the DH airplanes were designed. But even if it was, they had their hands full with the double slotted flap system, and likely had no interest in any crow/droop control mixer that would have complicated the aileron circuit any further.

What I can personally speak for, is that the crow configuration delivers additional benefits, and adds an extra margin of safety and control at low speeds, compared to similar aircraft (with similar aspect ratios, Re and loadings) that I have flown.

Another thing I can speak for personally (again on high aspect ratio sailplane wings), is that drooping both the ailerons and flaps to a high lift setting, then flying at low speeds in gusty mountain conditions, fairly often creates an unsafe condition. A small vertical gust will create a localized stall condition near a wingtip, and the aircraft starts a smooth roll towards that locally stalled tip. Because there's no buffet and the rest of the airplane is still flying, you don't immediately recognize it as a stall, so you just apply opposite aileron to "pick up" the wingtip. The aileron droops down some more when you move the stick, loading up that wingtip a bit more, and the localized stall gets bigger, and the airplane rolls further in the opposite direction than you are commanding it to roll. One more "opposite aileron" command, and a second or two later the airplane is on its way into a spin entry, and you NEVER had a big shaking stall warning buffet (because the wing stalled a little at a time).

The way we fixed that problem was to add a middle position on the flap detent rack, giving you half of the droop (flaps and ailerons). You used this new mid position in gusty conditions or when circling within a few hundred feet of the mountains.

Again the only thing I can personally say with absolute iron-fisted "Also Sprach Zarathustra" authority is that the crow configuration delivered a very safe, very steep, full control, low risk capability on approaches into short off-airport landings where there was no go-around available. Have there been plenty of STOL airplanes designed without it? Of course. Would I strongly consider incorporating this design feature into any STOL airplane I was building, using my own money, and with my own life at stake? Hell yes.
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Re: FankenmegasmallMaule

On the question of being experimental. It would be experimental, the question is whether it falls into the experimental "amateur built" category requiring the 51 % built by the individual for educational/rec purposes (which is normally the goal) or whether 51% was constructed by those operating commercially as a business even though no longer meeting certification. The second group (with mostly completed Maule parts) could likely qualify as experimental under the "exhibition" category. This category carries more flight restriction but most foreign military aircraft are flown like this and many completed imports that are not certifiable by US standards.

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