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FLIGHT DESIGN EXXTACY Repair And Tuning Manual

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Construction Basics
D Cell Repair
Rib Repair
Tuning
The Exxtacy is built with carbon fiber and Kevlar/Aramide honeycomb. The Exxtacy's main load bearing structure is based on a D cell, aptly
named because of its cross sectional shape.
Exxtacy
Repair and Tuning Manual
Exxtacy Construction Basics
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Summary of Contents for FLIGHT DESIGN EXXTACY

  • Page 1 D Cell Repair Rib Repair Tuning Exxtacy Construction Basics The Exxtacy is built with carbon fiber and Kevlar/Aramide honeycomb. The Exxtacy’s main load bearing structure is based on a D cell, aptly named because of its cross sectional shape. 1 of 20...
  • Page 2 The honeycomb layer is surrounded with carbon fiber, and the front, curved portion, of the D cell has fiberglass covering on the outside. The fiberglass covering provides a means of visually checking for damage, as any area that has been affected will be readily identified by white streaks. The spar is the vertical portion of the D-cell and is protected by the curved surface to the front.
  • Page 3 Along the back of the D cell, at the top and the bottom of the spar are long layers of carbon fiber belts that run the entire length of the spar. There are several layers of belts, near the nose, with decreasing layers toward the tips. These belts provide the main load bearing strength in tension and compression, with the front or curved portion of the D cell providing torsion stability.
  • Page 4 The controlbar is very much of the standard hang glider variety, except with significantly shorter downtubes. The front and rear is held by regular wire supports to the nose and the rear of the keel. Control cables are hooked to the corners of the basebar that run through a fiber pulley out to the actuator that raises the spoilerons.
  • Page 5 Then, using 60 to 80 grit sandpaper, sand through the outer layer of fiberglass, and the exterior layer of carbon fiber. Sanding should be at a 45-degree angle to the outside surface of the damaged area, so as to allow even load distribution of the repaired area with the surrounding structure. Below the sanded area you'll find the Kevlar/Aramide honeycomb.
  • Page 6 Sand this newly marked area down to the honeycomb, and scrap away the honeycomb down to the lower level of carbon fiber, keeping the sanding and the scrapping at a 45-degree angle to the surface. If you have to go down this far, you have now exposed the interior carbon fiber layer to an extent of inch on all sides outside the original damage to the exterior carbon fiber layer.
  • Page 7 The patches will be marked in three ways. First they must be marked for the size of the patch, itself. Second they must indicate the orientation of the patch, typically by an arrow pointing to the nose end of the spar. And third, they must be marked with a crosshatch to indicate the direction of the carbon fibers that the patch will be repairing.
  • Page 8 Place the newly cut carbon fiber sheets over the face down clear plastic pieces (that is flip the thin sheets of plastic over), such that the direction of the carbon fibers match the cross hatch directions indicted by the markings made earlier. Measure out epoxy resin and 1/2 as much hardener, and mix each together thoroughly using a disposable stick.
  • Page 9 Using a stiff brush, carefully apply the resin to the patches laid on top of each of the clear marked plastic sheets. Stipple the resin up to the indicated patch size on the plastic. Do not use a brushing motion, as this has the effect of pulling the carbon fiber weave apart. Also, use only enough epoxy resin to cover the cloth, cause it to adhere to the clear plastic, and to penetrate the cloth completely.
  • Page 10 Apply the first patch making sure to orient the arrow on the outside of the clear plastic in the correct direction (say with the arrow pointed towards the nose), and positioning the material directly over the affected area oriented along the carbon fiber strands on the interior surface of the D-cell. Once in position, and pressed into place, carefully remove the outer clear plastic template.
  • Page 11 Once filled, level the area using a straight edged stick. Fill back to the level of the surrounding surface of the D-cell, with no excess, and no lack of filler. Now that you've placed and interior surface patch, and fill above it, you can add the next two patches of carbon fiber. Be sure to peel away the clear plastic decal that indicates the direction of the patch, and the alignment of the fibers.
  • Page 12 Apply the outermost covering of fiberglass, in the same fashion. Use heavy duty Mylar to hold the patches in place and to smooth the epoxy resin to conform to the outer surface. Tape the Mylar tightly against the outer surface of the spar with duct tape. 12 of 20...
  • Page 13 Next, place Ethafoam tightly over the Mylar, and hold it on with packing tape or duct tape wrapped around the entire spar. Afterwards, support the spar with the patched area down. This allows gravity to keep the interior portion of the patch from sagging inward. 13 of 20...

  • Page 14: Rib Repair

    Rib Repair The ribs attached to the back of the D cell on the Exxtacy are constructed of carbon fiber tubes surrounding a foam square. Any cracks or breaks are repaired by first lightly sanding the carbon fiber layer on either side, to allow for adhesion of the epoxy resin. A tube of carbon fiber is slid over the area, extending a few inches beyond the break, or crack.
  • Page 15 Resin is then applied over the fiber, using a copious amount, such that the cloth is penetrated thoroughly to the lower layer. Plastic vinyl tape is then wrapped tightly over, and beyond the resined area. The epoxy resin will not adhere to the tape, and any excess resin will be squeezed out, and may be blotted away.
  • Page 16 Tuning You can tune the Exxtacy. To remove a turn, or tighten or loosen the sail, or to adjust the bar pressure. You may need to set the sweep within the appropriate parameters. Also, you can adjust the slackness in the control cables that attach to the corner of the controlbar.
  • Page 17 Before conducting this fix make sure that the sail is seated properly from side to side. Check to see that the Velcro straps that attach the sail at the nose are holding each side of the sail an equal distance from the end of the spar. Sight down the zipper when the sail is tensioned to make sure it is straight and inline with the keel.
  • Page 18 Flex wing pilots new to the Exxtacy will notice a dramatic decrease in pitch forces. Pitch pressure is a function of many factors, but mainly it comes from the twist of the wing. The twist in an Exxtacy is determined by the construction of the outer four ribs and, for all but the seventh rib, is fixed at the factory.
  • Page 19 Hold the glider with the keel parallel with the ground, and the wings level side to side. Using an object that is at 90 degrees to the keel, against the string, check to make sure that this perpendicular falls within the sweep marks made earlier.
  • Page 20  Vulture Squadron Productions 20 of 20...