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RF-4D Plans and wood parts printer friendly version
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Dan Rihn
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Posted Saturday, March 7, 2009 @ 04:46 PM  

I have experience in developing wood wing kits for the aerobatic aircraft I've designed. I have a friend who has a fantastic wood shop with excellent CNC wood routing and cutting capability. If there are a set of plans for the RF-4D available and if there is enough interest we could develop an "airframe kit". Complicated or tapering parts are no issue, varying size wood parts are no issue.

Any interest in developing new RF-4D's??

Dan Rihn
Rihn Aircraft Corp.

SteveBeaver
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Posted Sunday, March 8, 2009 @ 10:05 AM    YIM

The structure of the aircraft is quite complex and I suspect the investment would be substantial, but plans do exist and at least one person has reportedly obtained permission from Rene Fournier to build an aircraft. Rene's participation would be key of course.

If I read the mood of Fournier club members correctly though, there may be more interest in a modernized (partially composite) version of the RF4 than a reproduction of the original. As wonderful as we all think the RF4 is, aerodynamics and structures have come quite a way in 45 years

Steve

Dan Rihn
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Posted Sunday, March 8, 2009 @ 12:04 PM  

In my experience the issue with composites in homebuilding is the much greater up front investment in tooling and moulds. Then you have to "hope" you get customers and you are the only source, not a good situation. For a single place motorglider the cutomer base is awfully low at the get go. Maybe even too low for a "new" wood RF-4D. However it is a whole lot less money in time and material to program a wood cutting CNC.

I do agree that a much better performing RF could have a lot more interest. The 35/1 L/D Carat is getting a lot of attention. Pretty expensive for what you get, maybe a homebuilt 30/1 (Milan?) could be developed. I've looked at the Milan a bit, only 12 built, not many for sale. The one for sale right now a $30K and in Europe, so at least $40K here in the US. So, could a new one be built for less? My estimates say yes, but just barely and of course there is the time to design and build....

I always worry about designing and developing a motorglider. I think you could pour a ton of time and work into something that is not very good in the end. At least starting with an RF-4D one cold have some of these worries reduced.

OK, I'll go flying now and stop day dreaming....

Dan

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Posted Sunday, March 8, 2009 @ 12:26 PM    YIM

All very true. And then you have to think about the compromise that the RF4 is (and all aircraft are). Use a more modern airfoil, extend the ply leading edge back a little further, seal the spoiler boxes etc and now you have better glider, but maybe now it won't fly inverted or some other characteristic will no longer be as desirable (to you)

I'm guessing there would be a market for a few wing kits, a few rib kits (I'd buy one) and a few complete aircraft - but again, Rene would hve to give his OK - which he might.

Jorgen
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Posted Sunday, March 8, 2009 @ 07:52 PM  

Hi Guys,
you´ve poured so much wisdom into this thread that I (almost) hesitate to reply. Consequently I agree with what´s been said and would only add:

-Wood is so much nicer to work with- I became allergic to epoxy already when I built my first surfboard 25 years ago.

-As has been covered in other threads it is doable to remove the wing on the RF 4. Having an extra wing should therefore be feasible and extending the (already vast) options without doing away with the original one seems interesting, if it´s possible to do within a reasonable budget.

-As we´ve already agreed our high priest René should give his consent and also comment on whether this whole thought is considered to be blasphemy!

Take 5(b) just 4 fun/ Jörgen

Dan Rihn
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Posted Sunday, March 8, 2009 @ 10:40 PM  

oh I wouldn't dream of doing anything like this wthout Mr Fournier's blessing. I've had my designs copied and ripped off so I know what it's like and I'd never do that. I only recently joined this forum but I've been an RF fan for many years. I'm sort of between projects so I have a lot of velocity but no vector!

The last several years I've enjoyed X/C soaring in my ASW-20. I have a 2 hour drive each way to get to a good X/C gliderport. That plus I am crewless (some would say clueless...but that's another topic) so I've had a dream of operating a motorglider from my home airport in the LA basin. Years ago there was an RF-4D operated from my home airport so I know it can be done. See the story by Collin for more on that RF-4D, it's now being rebuilt. Anyway I've flown the Stemme S-10VT, Ximango and the Lambada. I liked all of them, they each have some good and bad points but something about the RF's still intrigues me.

Back to the original question- If someone who has contact with Mr. Fournier and access to the RF drawings, I would offer my help first in evaluating a kit RF and if feasable taking it to the next step.

thoughts???

Dan

jb92563
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Posted Monday, March 9, 2009 @ 03:55 PM  

Dan,

Yes, count me in on working on a few RF4D kits.

I'm also crewless in SoCal....Schreder HP-11

I do have a Grob 109 motorglider but you can't do aerobatics, although its a good tourer.

The RF4D is not a great soaring machine but with an engine and aerobatics on tap there is other fun to be had, so I think the soaring is best left to the pure soaring machines with retractible motor pods.

My interest is gracefull long line aerobatics and just plain buzzing around and having fun, and a poor mans "Spitfire" in the form of an RF4D sure has the right stuff to fill that bill.

The performance, cost and maintennance are all good if not great, plus I don't have to go get any more ratings and can basically fly till I'm old and more grey.

A fellow in France is building from a set of plans so I think we would want to communicate our desires to Rene and see if he supports the home building effort and can get us a copy of the plans.

I think the composites can fit in where they make sense but primarily wood would seem to be the quickest way to go.

As you said once we start cutting wood having CNC patterns would allow us to make a few kits worth so there are spares and patterns etc for everyone.

The Guy from France "Phillippe" already has some CNC files as I understand it, or is currently creating them.

Ray

Jorgen
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Posted Monday, March 9, 2009 @ 06:25 PM  

Dan,
thanks for your inspiring inputs, it´s a great idea to see if Forunier kits are feasible. I used to own a half share of an LS-3 (once the rival to ASW-20 on the comp´s) so I can imagine you enjoy XC. I have to say though that the Fourniers more than make up for lack of performance in availability, versatility (you can´t get a Stemme in the air off a grass strip in 150 meters) and sheer flying fun, so I don´t miss the Ls-3. In short, the Fourniers have "it".

No offence Ray, but I don´t quite agree with you that the RF4D is not a great soaring machine- it´s just that you need 1 m/s more lift to be able to soar compared to the pure soaring machines. The handling during soaring is quite agreeable (at least considering you´re carrying an engine aloft with you)and actually I was almost able to keep up with LS-3 "SE-TTM", climbing power off in a strong thermal a couple of years ago. I think a 15 m wing similar to the SFS-31 Milan (maybe a lighter wing could be built?) could be interesting. Point taken Steve, but if it´s intended for soaring, it doesn´t have to fly as good upside down as the original wing does.

I´d like to add one more point on the composite versus wood discussion: there is no such thing as "wood fatigue". My buddy Mikael still happily flies his 1918 Bleriot XI, the fabric is new but most of the woodwork is original. I don´t know if SE-XST will still fly in 2050, but I see no reason why not.

Regarding RF4D´s- made at the Sportavia factory in Dahlemer Binz, the "D" stands for "Deutchland" (Germany) to distinguish from the RF 3´s and a couple of RF 4´s made at the Alpavia factory in Gap, France. So Dan, if you guys start making Fourniers in the US, they would be RF4U´s!

See- the slogan is already there....

Take 5(b) just 4 fun/ Jörgen

[Edit by Jorgen on Saturday, March 14, 2009 @ 03:40 AM]

Bob Grimstead
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Posted Monday, March 23, 2009 @ 09:04 AM  

Hi Dan,

As an aerobatic newbie and enthusiast, I have huge respect for your airplanes, and it would be great to see you become involved in building Fourniers. Welcome to our world.

I too think that it is best to stick with wood. The RF4's structure is good for +6/-3g limit, and we know the test example didn't break until 13.8g. That's quite enough for me.
I've flown my 40 year-old Fourniers regularly to +6/-3g and ocacasionally (inadvertently) to nearly +7/-3.5g. Wood is good!

René Fournier's address is:
La Halbuterie
37270
Athée sur Cher
France

Although no longer young, he is still fit and vigorous and seems pleased to help all Fournier enthusiuasts. He's rightly very proud of his family of airplanes and their pilots. His son can translate from English into French for him.

Both Matthew Hill and Dave Bland (lifetime British Fournier enthisiasts) have RF4 fuselages and tailfeathers but no wings. A common accident is to go through a hedge and smash the wing, leaving the fuselage, engine, tail and all the rest OK.
Matthew even has almost all the metal wing components, although some might only be good enough to use for patterns/templates. I think you could sell a couple (maybe more) of wings or wing kits (minus fabric) pretty well straight off, but of course the spar is the difficult part to make. But the last second-hand wing (complete, un-covered) I heard of went for around $10,000US, so since Fourniers tend to be owned and operated by frugal or impecunious folks, there may not be any profit in that. At a guess, I'd say you might sell complete new wing kits (all the wood plus all the metal components) for $20k. That might just not be profitable.

If proceeding with a complete 'new' RF4, I would recommend using the Jabiru 2200 engine. It is lighter than a 1200/1400cc VW, but a very similar size and generates 80 horsepower at the same rpm (so it can use a similarly short and 'un-draggy'propeller) and incorporates an alternator and electric starter within that weight. The only problem is that these ancillaries are wider, and protrude further out of the back of the engine than the Rectimo's magneto, so a larger hole would have to be cut in the firewall to retain the center of gravity. That in turn would mean the firewall would have to be made stronger.
Last I heard, these motors sell new for under $10k US, but Jabiru factory reconditioned ones can be bought for less. A new 1400VW motor, made up from new/old stock parts currently costs around $6k here in Britain. Using the 1400cc VW I cannot quite maintain height during a 4-6 minute aerobatic sequence. Using the Jabiru I most definitely could do so, and probably include some more difficult manoeuvres. Unfortunately neither the Jabiru nor the VW have inverted fuel systems, but the RF4 is so clean that with a little more power it could regain while erect any energy lost while inverted.

If you would like to fly either of mine, you have an open invitation to do so.
One is usually near London Gatwick airport in England, and the other is near Perth airport in Western Australia.

If you do go into Fournier production, even in a limited way, if it is of any help, as an aviation journalist I reckon I can get you coverage in Kitplanes (USA), Pilot (Britain), aerokurier (Germany), Pilotes (France), Flygrevyn (Sweden) and Volare (Italy) and probably in Australian Aviation and World AirNews (South Africa) too. Maybe more.

I look forward to hearing of your progress, and hope I can help.

Yours, Bob

Dan Rihn
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Posted Tuesday, March 24, 2009 @ 10:44 AM  

Thanks Bob,
Here are my thoughts so far on building new RF-4D’s
I’ve taken a look at the RF-4D drawings and made a few observations. Lots of small parts, lots of drawings. None of the parts individually are very complicated, just a whole lot of them in general. The details of the drawings are very good, probably due to it being a factory built aircraft. Very impressive, this is not a simple “homebuilt”. Due to my non-existent capability in the French language (ironically my ancestors are French); it’s a little tough to understand some of the details. I think that with the drawings and with an existing airframe we could come up with a new copy of the RF-4D. Then the question of how much and what is the market? Another approach could be that if someone needs a new airframe part we could copy it. Bob mentioned people needing new wings, if we had a damaged one we could copy that as well.

Dan Rihn

Bob Grimstead
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Posted Thursday, April 2, 2009 @ 05:39 AM  

For those of you who want to build an RF4, I refer you to Matthew's post:

Ray,
I have many varied parts including main structures for the RF-4D, please contact me at Gawek68@gmail.com
Matthew

jb92563
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Posted Thursday, April 2, 2009 @ 06:23 PM  

I have inquired with Matthew about his parts to see what he has.

Perhaps a a comercial venture the RF4D is not really viable but I'll bet we could get a half dozen home builders interested in making a few and as a joint effort we could all "mass produce" certain sections and share with each other.

The whole setup/tooling thing takes time but the cutting then goes quickly to make a good number of parts and spares.

Making just one seems like a poor utilization of opportunity.

Ray

joethepro
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Posted Wednesday, April 22, 2009 @ 12:19 PM  

DAN I HAVE A COMPLETE AIRFRAME AND A COMPLETE PROJECT AIRCRAFT (PICTURES ON THE WEB SITE) WITH SOME SMALL RIB DAMAGE AND CARRY THROUGH DAMAGE I LIVE IN COLUMBUS OHIO I WOULD LOVE TO TALK TO YOU CALL 614 565-6319 ANYTIME. JOE FOLEY

http://www.cfiamerica.com/4076-RF4D.html

philippe
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Posted Thursday, October 22, 2009 @ 05:30 PM  

hello from france.

I am the french guy who is building a replica RF4 with the originals plans from MR FOURNIER.

I will show you soon the pictures of building my aircraft on my own web site.

again few days to wait...

if someone want more informations about it, I give you my email: phi.julien@free.fr

bon vols.

Jorgen
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Posted Friday, October 23, 2009 @ 07:43 AM  

Merci Philippe pour votre collegialité,
you will find a huge interest for your project on this forum. I can´t wait to see your pictures!

May the 4´s be with you/ Amitiés, Jörgen

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