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2006 Progress Highlights
Perspective and Retrospective
Most of 2005 was spent finding up professionals with which to work, then working through the conceptual design process. Our professional engineers helped us develop a CAD model that defined wing and canard sizes, fuselage shape, reasonable expectations regarding weights, power required, and mission objectives. This year we will start building full-size prototypes of the AirCar and the ElectriCar. This process will help us solve many of the problems inherent in building a flying car and also a light-weight, aerodynamic electric car.
January 2006
Received final report from Darcorp, including
Performance Sizing Results and Report
on CFD (Computational Fluid Dynamics) study. Results were better than hoped for. Started
the search for people to help fabricate the AirCar and ElectriCar. Since the
first prototype of the AirCar would be a non-flying but driveable vehicle,
Pacific Roadster, a car fabricator in nearby Salem, Oregon was selected. The
company has a vast amount of experience fabricating cars, boats and some airplane parts,
has an awareness of aviation from being licensed pilot and aircraft owner, and is currently building replicas of Cobras. RULE:
Start out with a small project for each person you work with, then increase
gradually.
February 2006
Using the cad files received from Darcorp, had full scale fuselage cross-sections drawn, then cut out twenty plywood cross-sections and put them together in frame. RULE: Don't start someone on the next phase of a project until their current phase is completed.
March 2006
The fuselage cross-sections were covered with fiberglass cloth and the shaping was begun. ElectriCar wing sections were also created so work could begin on the wings. Although the Darcorp CFD study showed the AirCar to be very aerodynamic, Reed Schmidt, a University of Kansas industrial design graduate was hired to improve the look of the vehicle without changing its shape. The appearance of the vehicle was vastly improved by changing the window and door lines, adding headlight and taillights. The vehicle was also changed to have four doors. QUOTE: "At first, people refuse to believe that a strange new thing can be done, then they begin to hope it can be done, then they see it can be done - then it is done and all the world wonders why it took so long. Secret Garden, Frances Hodgson Burnett.
April 2006
Work continued on the fuselage and wings. Selected wheels and hubs from the 1988-93 Geo Metro. Work started on the GPU computer control. RULE: Educate yourself so your professionals respect your knowledge of the subject.
May 2006
Work continued on the fuselage, including the location and lines for doors and windows. The wheel pants & canard frames were formed. RULE: Get something measurable done each day. Plan, but don't waste time just thinking about things.
June 2006
Fabrication work continued on the fuselage, wings, canards and wheel pants. The first road test of Beetle with electric motors was completed. The Beetle required 9.5Kw (12.6 HP) to maintain 40 mph and 12Kw (16 HP) to maintain 50 MPH. Both speeds use about 235 watt hours per mile. The goal for the ElectriCar is less than 100 watt hours per mile, less than half the power required for the Beetle. QUOTE: "If you don't have a consensus that it is nonsense, you don't have a breakthrough." Burt Rutan, Scaled Composites
July 2006
The fuselage pattern (also know as the plug) was finally completed, and work began on the fuselage mold. Work continued on the ElectriCar wings, canards and wheelpants. RULE: Visualize success daily.
August 2006
Started working with Mark Olson, a Portland, Oregon-based patent attorney to complete patent applications for the design of both vehicles. Continued work of the fuselage molds, and created molds for wheel pants. RULE: Pay your vendors on a timely basis, but keep them motivated to complete the project.
September 2006
Fuselage molds are completed and removed from fuselage plug. First set of wheel pants are completed. RULE: Don't hire an electrician to solve your plumbing problems.
October 2006
The three pieces of the fuselage mold were reassembled and work was begun on the first fuselage skin. Molds for the creation of the windows were created and canard plugs and wing plugs were fit to fuselage plug. Built a 72x44x18" oven for thermoforming of plexiglass windows. Both design patent applications were sent to US Patent and Trademark Office. QUOTE: "Just what makes that little old ant think he'll move a rubber tree plant? Everyone knows an ant can't move a rubber tree plant. But he's got high hopes. He's got high hopes. He's got high apple pie in the sky hopes. So any time you're getting low 'stead of letting go just remember that ant. Oops there goes another rubber tree plant." Jimmie Van Heusen, Song Writer
November 2006
Continued work on ElectriCar wing and canard plugs. First fuselage skin created and removed from fuselage molds. This first fuselage skin will be used to create door molds, size and shape the steel frame, and fit the Ground Propulsion Unit. RULE: Complicated explanations come from either not understanding the process or confusing the results.
December 2006
ElectriCar wing & canard plugs completed and molds started. Work started on the chrome-alloy steel tubular frame. RULE: The truth of the matter is that every part of this project will be difficult.
