Summary of Contents for PPGPlans Skybolt V2
- Page 1 Skybolt V2 Construction Manual Revised Version: January 2010 Property of www.ppgplans.com – Do not duplicate or make public. Last Revised Version: January 2010 © PPGPlans.com...
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Page 2: Table Of Contents
Skybolt V2 – Construction Manual Index Page Warnings & Disclaimer Acknowledgements Tools Used Tips Layout Frame - Center Section Building The Hoop Lower Cage Section Upper Cage Section Hoop Connectors Final Assembly J Bars & Harness Engine Mounts Fuel Tank Mounting... -
Page 3: Warnings & Disclaimer
Acknowledgements The initial design of the Skybolt V2 (& V1) frame is credited to Jeff Baumgartner, pioneer of the self-made paramotor. Jeff Goin, as president of USPPA and in favor of the growth of the sport worldwide acquired the... -
Page 4: Tools Used
Use a metal cutting saw (hack saw) for cutting chromoly, a carbide tipped power cutoff saw is fine for aluminum, but will destroy itself on chromoly. Make sure your work surface is flat. Property of www.ppgplans.com – Do not duplicate or make public. Last Revised Version: January 2010 © PPGPlans.com... -
Page 5: Layout
Scale up the layout drawing on this work surface. Pictures of a flatbed trailer used as a work surface. Property of www.ppgplans.com – Do not duplicate or make public. Last Revised Version: January 2010 © PPGPlans.com... -
Page 6: Frame - Center Section
Then one end of the 16 3/8 chromoly tube into the top ¾ inch hole in the vertical tube. Now install the second vertical tube onto the assembly. Property of www.ppgplans.com – Do not duplicate or make public. Last Revised Version: January 2010 © PPGPlans.com... - Page 7 ¼ of an inch of the horizontal tube sticking out in front of the vertical tube. The diagonal brace tubes will be installed later. Property of www.ppgplans.com – Do not duplicate or make public. Last Revised Version: January 2010 © PPGPlans.com...
- Page 8 7) Drill ¼ inch holes ½ inch in from each side of joints in square tubing. Lift the assembly out and use AN4-14A bolts to bolt together (1 bolt, 2 washers & 1 nut per hole) Leave the bottom square tubes off yet. Property of www.ppgplans.com – Do not duplicate or make public. Last Revised Version: January 2010 © PPGPlans.com...
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Page 9: Building The Hoop
6) Remove the chromoly tube and cut the 0.875 tube off at the outside edge of diagonal brace mark on your work surface. 7) Repeat this process for the other lower hoop tube. Property of www.ppgplans.com – Do not duplicate or make public. Last Revised Version: January 2010 © PPGPlans.com... - Page 10 Tip: Once again, it is strongly recommended to practice these bends on some thinwall conduit, it is very cheap and will save you money in the end. Property of www.ppgplans.com – Do not duplicate or make public. Last Revised Version: January 2010 © PPGPlans.com...
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Page 11: Upper Cage Section
4) Next slide the short ends of the radial tubes onto the chromoly stubs, Slide the radial tube to hoop connectors into the longer ends of the radial tubes, 0.750 radius connectors in the top Property of www.ppgplans.com – Do not duplicate or make public. Last Revised Version: January 2010 © PPGPlans.com... - Page 12 (inserted but not permanently connected) with the lower ends of the lower hoop sections at the Outside edge of diagonal brace line. Property of www.ppgplans.com – Do not duplicate or make public. Last Revised Version: January 2010 © PPGPlans.com...
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Page 13: Hoop Connectors
NOTE: BE SURE THE TUBE IS AT LEAST 2 INCHES LONGER THAN THE DISTANCE BETWEEN THE 60 DEGREE LINES WHEN IT IS LAYING ON THE WORK SURFACE ALONG THE INSIDE HOOP DIAMETER CIRCLE. Property of www.ppgplans.com – Do not duplicate or make public. Last Revised Version: January 2010 © PPGPlans.com... - Page 14 A small amount of grease works wonders here. Mark the tubes so you can always make the same joint for the rest of the build. Property of www.ppgplans.com – Do not duplicate or make public. Last Revised Version: January 2010 © PPGPlans.com...
- Page 15 Repeat these procedures for the other lower hoop tube. Then use the same procedures for installing the connectors to the 0.750 hoop section, being sure they slide into the lower sections Property of www.ppgplans.com – Do not duplicate or make public. Last Revised Version: January 2010 © PPGPlans.com...
- Page 16 ½ inch from the ends of the radial tubes, all the way through for double button clips, do your best to drill these straight and centered, the clips will work better. Insert the clips. Finished radial tube and hoop joints Property of www.ppgplans.com – Do not duplicate or make public. Last Revised Version: January 2010 © PPGPlans.com...
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Page 17: Final Assembly
Note: You can also bolt the diagonal brace tubes to the 21 inch chromoly tube but it is not necessary as the lower hoop tubes will trap them in place. Property of www.ppgplans.com – Do not duplicate or make public. Last Revised Version: January 2010 © PPGPlans.com... - Page 18 Finally drill the ¼ inch hole all the way through for double button clips to connect the lower hoop sections to the bottom 21 inch chromoly tube. Property of www.ppgplans.com – Do not duplicate or make public. Last Revised Version: January 2010 © PPGPlans.com...
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Page 19: J Bars & Harness
J bar, with a nylock nut on the backside. Cut off and bolt protruding past the nut and file smooth. Property of www.ppgplans.com – Do not duplicate or make public. Last Revised Version: January 2010 © PPGPlans.com... - Page 20 It can be done! Drill a ¼ inch hole through the diagonal brace and J bar and install a double button clip or AN4-14A bolt. (Picture 16) Property of www.ppgplans.com – Do not duplicate or make public. Last Revised Version: January 2010 © PPGPlans.com...
- Page 21 Melt hole on the strap about 1 inch above the end, attach to the tube and tighten with a wide washer as seen below. Property of www.ppgplans.com – Do not duplicate or make public. Last Revised Version: January 2010 © PPGPlans.com...
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Page 22: Engine Mounts
Shown below are some examples of the Paracruiser tank mounted in a V2 frame. Property of www.ppgplans.com – Do not duplicate or make public. Last Revised Version: January 2010 © PPGPlans.com... -
Page 23: Finish
A couple of 4-6 inch off road skate board wheels make a good choice. Property of www.ppgplans.com – Do not duplicate or make public. Last Revised Version: January 2010 © PPGPlans.com... -
Page 24: Appendix A - More Photes
Appendix A - More photos. Pull Start pulley attached to side vertical bar Finshed Frame Property of www.ppgplans.com – Do not duplicate or make public. Last Revised Version: January 2010 © PPGPlans.com... - Page 25 Close up view of finished netting at the sides. Finished Unit Property of www.ppgplans.com – Do not duplicate or make public. Last Revised Version: January 2010 © PPGPlans.com...
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Page 26: Appendix B - List Of Materials
2024 T3 or T4 aluminum flat 2 x 0.250 wall 18 inches BOLTS AN4-14A AN4-15A AN4-16A AN4-24A AN365-428A NUTS WASHERS AN960-416A (SMALL) AN970-4 (LARGE) Property of www.ppgplans.com – Do not duplicate or make public. Last Revised Version: January 2010 © PPGPlans.com... -
Page 27: Appendix C - Other References
Appendix C – Contacts & References Skybolt V2 Cosntruction Manual & Specs (This Manual) www.ppgplans.com Material Suppliers Aircraft Spruce www.aircraftspruce.com Wicks Aircraft www.wicksaircraft.com Equipment Suppliers Motor AeroCorsair www.aerocorsair.com Harness (Under arm comfort bar) Apco www.apco.com Paratoys www.paratoys.com AerotThrust www.aerothrustppg.com Francesco De Santis www.powerglider.biz... - Page 28 Property of www.ppgplans.com – Do not duplicate or make public. Last Revised Version: January 2010 © PPGPlans.com...
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