3D printed gear fairings project

[BRS]

I started with this little project for the fun of it. I'm doing this on my Glasair Sportsman but thought I would also try this on the sonex as well. So I thought I'd share a few pictures in case anyone is interested.

First I drew the entire full length fairing but printed in short segments so they don' crack with gear flex

The segments snap onto the gear leg and get aligned with a hing pin. Final assembly would involve something like RTV to help secure.

Fianally they are covered with vinyl wrap. This is just a short test length.

Still to do is to refine the 3D print process to get the exterior nice and smooth. Also remove most of the excessive interior support.

[Bryan Cotton]

Very cool Brock! Let us know how it works out.

[tps8903]

I started with this little project for the fun of it. I'm doing this on my Glasair Sportsman but thought I would also try this on the sonex as well. So I thought I'd share a few pictures in case anyone is interested.

2023-09-20-14-01-16-069-01.jpg

2023-09-22-14-58-46-589.jpg

2023-09-22-15-18-53-528.jpg

Still to do is to refine the 3D print process to get the exterior nice and smooth. Also remove most of the excessive interior support.

Very cool. I've wondered about various 3D printed parts like Fairings and such, or cowl flaps.

For gear legs I bought streamline pvc tubes from a local ultralight airplane place at KDED. I cut the trailing edge and put a piano hinge for easy removal etc. Was cheap, easy and super effective.

http://www.uflyit.com/streamline_fairings.htm

[BRS]

I did the u-flyit fairings on my sportstman several years ago (have an article on it if any one wants instructions). Locking them in place was the biggest challenge but that has been figured out by another sportsman owner. Since they have been sitting on the shelf for awhile I decided to try this 3d Print idea. This actually started as a project to print spats (still in progress) since my tires are too large for pants. Here is a pic of the prototype spats...

[NWade]

Keep in mind that most 3D printer materials (both filament and resin-type) do not tolerate UV exposure well over time. Some filaments do slightly better, but most of those are a real pain to use (such as ASA). PETG is one of the best compromise solutions, being reasonably straightforward to use and print with, yet holding up OK outside for a few years.

Note also that a simple folded piece of sheet metal or hollow composite layup will be lighter than a bunch of 3D printed segments that require infill for strength. The best use for 3D printing and a part like this is probably to use the 3D printer to make a mold, enabling a smooth and precise fiberglass or carbon fiber layup. (Shout out to the “Easy Composites” YouTube channel, who have lots of layup tutorials including how to use 3D printed molds)

Good luck,

—Noel

[BRS]

Keep in mind...

—Noel

Noel, You miss the point....

" this little project for the fun of it." from the firs post. Yes, I only print nowadays with PETG