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Thread: Sweepwings 48” Juggernaut EPP wing build

  1. #1
    Instructor Pilot appelm's Avatar
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    Sweepwings 48” Juggernaut EPP wing build

    ** July 2016 update **
    Couple more years and a new build.. see the update a few pages down or click below:
    http://fpvlab.com/forums/showthread....l=1#post803310




    ** August 2014 update **
    After suffering some serious damage, I rebuilt the Jugg and made some changes that I would recommend. See the updates later in the thread here: http://fpvlab.com/forums/showthread....l=1#post554804 and it has a new look:


    ****
    Original post 12-November 2013:
    ****

    Well, its snowing outside today so instead of flying, I have time to write this build thread. I just finished building a 48” Juggernaut wing by Sweepwings. After several flights, I am very pleased with this wing. Here’s the final result:



    There’s a thread about this wing and its little and big brother here: http://fpvlab.com/forums/showthread....ght=juggernaut

    The wing can be purchased at SierraRC.com.

    The wing is tough and solid, easy to launch, and can carry a decent size payload. At 48”, it’s the perfect size for me as it can fit in the trunk of my car (I have a pretty big trunk.. YMMV). So far, I’ve only been able to fly it in pretty high winds and I’m amazed at how well it handles. It practically ignores 17mph winds.

    Ruben, the maker of these EPP foam wings, has been incredibly helpful during my build. He has readily replied to questions regarding the build via facebook and I really appreciate his help and knowledge. I also want to thank the Checking in From Northeast US thread team for their help and all the TBRC guys who gave me great advice on the basement-rc.com forum.

    So here is my build. Its my first wing build of any complexity coming from flying a 900mm Popwing which was a snap to put together. This is more labor intensive to say the least but it’s a labor of love for me. The quality of the foam cutting is superb and it just made me want to build the nicest wing I could.

    I hope these pictures are helpful to anyone considering this wing. I will say the youtube build videos for the Juggernaut that Ruben put together are really excellent and detailed and should certainly be viewed by anyone looking to build this wing.

    Components:
    Juggernaut wing: http://www.sierrarc.com/index.php?ma...kvk4cveu017786
    Turnigy NTM 35-36A 1400kv Motor: http://hobbyking.com/hobbyking/store...arehouse_.html
    --> Upgraded to Cobra 2826-1470kv motor with 9x6 prop:
    http://innov8tivedesigns.com/parts/b...-motor-kv-1470
    Turnigy PLUSH 100 amp ESC: http://hobbyking.com/hobbyking/store...arehouse_.html
    APC 9x6 prop: http://www.readymaderc.com/store/ind...roducts_id=836
    600mw 1.3ghz Vtx: http://www.readymaderc.com/store/ind...roducts_id=914
    Side-fed Cloverleaf antenna from IBCrazy
    Dragonlink V2: http://dragonlinkrc.com/v2/
    PZ0420 flight camera with 2.8mm lens: http://www.securitycamera2000.com/pr...-Menu-DNR.html
    Camera case for PZ0420: http://www.securitycamera2000.com/pr...udio-Hole.html
    Hitec HS-645MG servos: http://www.readymaderc.com/store/ind...roducts_id=165
    Control Horns: http://shop.dubro.com/p/heavy-duty-c...horn-for-40-91
    Screw Clevis: http://shop.dubro.com/p/2-56-spring-...is?pp=12&pp=12
    Solder Clevis: http://shop.dubro.com/p/2-56-solder-...is?pp=12&pp=12
    Pushrod: http://shop.dubro.com/p/12-2-56-thre...on=recommended
    Balsa elevons: http://www.amazon.com/dp/B00081ANS0/..._26725410_item
    --> replaced with tapered balsa http://www.gravesrc.com/BALSA_USA_3_...n_p/bal244.htm
    EagleTree Vector: http://www.readymaderc.com/store/ind...oducts_id=2307 (don't need below anymore)
    Low Noise RMRC 3A Regulator (UBEC): http://www.readymaderc.com/store/ind...oducts_id=1297
    Discovery buzzer: http://hobbyking.com/hobbyking/store...arehouse_.html
    GoPro Hero3 Black
    Dual 4200mah 35C 4S batteries (Kypom): http://www.readymaderc.com/store/ind...roducts_id=898




    Day 1:



    Everything comes very well packed:



    Foam, motor mount, Gopro strap, spars, instruction sheet, winglets, bay lid, laminate



    The instruction sheet is basic but detailed enough and along with the build videos, you have everything you need to know:



    Because the foam is hand-cut, it comes with a lot of remnants from the cutting process. It still needs to be prepared for the build.




    The remnants can be carefully peeled off. I used a power sander to get it really clean and smooth.




    Getting ready to glue the 3 main foam pieces together:



    Initially I used brown Gorilla Glue to glue the EPP foam parts together. But I had a bit of a disaster with that. The glue expanded much more than expected and the 2 pieces I glued together separated. Using pins and/or tape is advisable. For my second attempt though, I decided to glue the pieces together with ShoeGoo which I’ve used before and think holds the pieces together very well.



    Installing the spars using the instruction sheet for placement measurements:






    I actually messed up a bit with the spars.. There are two different kinds of spars. 3 are thicker and stiffer, and are supposed to be your main lateral spars. The other thinner spars are for the leading wing edge and the front center section. I used 2 of the thicker spars for the leading edge without realizing the difference. It still seems very stiff and I’m not too concerned. I might add another thick spar laterally if I feel it needs it. Just take note of this and do use the thicker spars laterally.

    The spars are glued with brown Gorilla Glue which dries white ad expands quite a bit. Once Dry, I sanded the joints down again with a power sander to get it nice and smooth:




    Here’s a size comparison at this point with my 900mm popwing. The jug doesn’t have elevons attached yet.




    Continued next post...
    Last edited by appelm; 11th July 2016 at 01:50 PM.
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  2. #2
    Instructor Pilot appelm's Avatar
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    It’s a little nerve-racking cutting a big hole in your beautiful new wing for the battery bay but you gotta do it!




    The Kypom 4s batteries I’m using fit well in this size battery bay. However, in the end I decided I wanted more room for electronics and so I cut out 2 more battery bays on the wings (see below):




    Cutting out the battery bay floor:





    Gluing in the battery bay floor with white Gorilla Glue and then a picture after sanding it all down:




    Finally, spray paint with satin black Krylon Fusion paint to cover up the white glue:



    Now, glue on the motor mount with white Gorilla Glue. I bought clamps to hold it in place and put a weight on top as well. I let this dry overnight. You want this to be very solid.



    Using the accessory kit for the motor mount as a template to drill holes for the motor:




    Have to cutout some of the foam on the top of the wing to access the screw holes. Also, used a drill sander to smooth out the edges of the holes.



    Continued ...
    youtube.com/user/Appelm1
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  3. #3
    Instructor Pilot appelm's Avatar
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    Sweepwings 48” Juggernaut EPP wing build

    Now, I laid out components on the wing to get a sense of placement and CG. I was very careful with both front/back and left/right CG.



    Its hard to mark this black EPP foam.. But I found that my daughter’s crayons worked really well:



    I used a solder gun to cut out all the bays. I just took one of the metal tips it came with and reshaped it into more of a rectangular shape to help me cut wider paths through the foam. I used other finer tips on the solder gun to cut wire paths and tunnels into the main bay







    Here you can see the battery bay cutouts on the wings. My placement of the servos is a little close to the battery bays. There actually is no wall in one spot. I should have moved my servos out a bit more in each direction possibly beyond the battery bay. The space is a bit limited where I put the servos and they are big servos.. But it still works the way I did it.



    Time to make the elevons.. I bought 3/8” balsa online. Because I’m running a somewhat powerful 4S setup on this wing, balsa elevons are recommended.





    The balsa is easily cut with a snap razor knife.





    Beveling the inside edge is pretty simple too and necessary to get good down movement on the elevons.

    Painting the elevons:


    Wiring up all the electronics on the bench. I wanted to test everything before installation so I wouldn’t have to pull out equipment once installed:



    All equipment installed in bays. I used Velcro to connect some parts (receiver, vtx) and gorilla glue for others (ESC, servos). Velcro sticks much better after applying some goop to the bottom of the bay and letting it dry.



    I chose to install equipment first and then laminate. You can laminate first as Ruben does in his build videos. But I wanted all the equipment and wires to be covered by one sheet of laminate to make it as clean as possible.






    All laminated including elevons:


    Note: I later reshaped my elevons a little to make them more tapered toward the center.

    Here’s the final product with all the wiring done:







    Maiden launch (filmed by my 9yr old daughter so excuse the shakiness):




    Hoping for some better weather soon to put together some FPV footage..
    Last edited by appelm; 12th November 2013 at 02:19 PM.
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  4. #4
    Tinkerer Mochaboy's Avatar
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  5. #5
    Instructor Pilot appelm's Avatar
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    Sweepwings 48” Juggernaut EPP wing build

    Thanks! That's a Mochaboy cloverleaf on there. Cheers.

    Btw in the pictures above I used quick-connects on my servo-pushrod connection. But they came loose on a hard landing so I replaced them with solder clevises and added carbon fiber tubing around the pushrods to reduce flexing.



    With 2x3300 4s lipo's I'm easily getting 30 minutes flight time. I bet I could get 40 if I pushed it. The bays can fit my Zippy compact 3700mah lipo's too.
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  6. #6
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    Awesome build thread. I'm building a Juggernaut too, so very useful

    One quick question. How did you wire up your osd to the 4s video link board? I know there is a servo connector on it with ground and signal. But should I hook it up to my video out or in wire on my osd. I'm using a Myflydream teleflyosd (I have a ezosd too)

    Sorry for my bad English (I'm from the Netherlands)

  7. #7
    Instructor Pilot appelm's Avatar
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    The 4S video link board by IBCrazy is really nice. It does everything in a neat package.

    Click image for larger version. 

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    The video bypass has a servo connector on it but I actually cut that off and added a JST female connector to it. Then that JST connector fit right into my storm OSD Video-in and Video-out pins. Your setup may be different. But on the Storm OSD, you have 2 sets of 3 vertical pins like so:

    Video in Video out
    Video Video
    Power Power (12v)
    Ground Ground

    I just connected the JST between the two Video pins and left the power and ground un-used since the camera and vtx are being powered by the IBCrazy board.

    Hope that helps.
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  8. #8
    I get people to do stuff. TheBender's Avatar
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    Excellent build thread Marc! I might have to get one of these too...

  9. #9
    Instructor Pilot appelm's Avatar
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    Quote Originally Posted by TheBender View Post
    Excellent build thread Marc! I might have to get one of these too...
    Thanks Merrill.. I think you need one.. I can't wait to fly it at your place
    youtube.com/user/Appelm1
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  10. #10
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    Quote Originally Posted by appelm View Post

    I just connected the JST between the two Video pins and left the power and ground un-used since the camera and vtx are being powered by the IBCrazy board.

    Hope that helps.
    Thanks. Will try it out

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