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C-130 build from Cargotrans kit / GWS reincarnation

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tudordewolf

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Another "challenge" build, this one revives an early 2000's classic, the GWS C-130, which is apparently the origin of this kit - GWS is defunct, though their website still lists this very model, It is now sold by MD-hobby, who also seems to be offering the GWS P-38.

I wasn't in the hobby yet during GWS's heyday, but from my readings of the forums there were known for being practically as much work as a balsa kit due to the brutally simple starting point - unpainted, uncut, styrofoam pieces unadorned with any hardware.

It was my first time using an airbrush, and it was very rewarding turning this:
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Into this:
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more pictures and details to follow
 
Another "challenge" build, this one revives an early 2000's classic, the GWS C-130, which is apparently the origin of this kit - GWS is defunct, though their website still lists this very model, It is now sold by MD-hobby, who also seems to be offering the GWS P-38.

I wasn't in the hobby yet during GWS's heyday, but from my readings of the forums there were known for being practically as much work as a balsa kit due to the brutally simple starting point - unpainted, uncut, styrofoam pieces unadorned with any hardware.

It was my first time using an airbrush, and it was very rewarding turning this:
View attachment 253098

Into this:
View attachment 253099
more pictures and details to follow
I love following along with your airplane builds! I love airplanes, sometimes even more than surface stuff. And there are days when the thought of sitting here building a balsa kit pops into my head, and I know I would love it, but I just don't have the room left to add airplanes to my mess. I believe that stems from watching my dad and brother build a large RC plane.

So yeah, let's go!
 
Thanks everyone!

The first challenge was converting it to a 4-engine layout. It's a quirk of the kit that it's sold as a Cargotrans C-160, a real plane which somewhat resembles a C-130 with 2 engines instead of 4, but it's clear that the foam pieces are those of a C-130, the biggest giveaway being the dolphin nose.

The included nacelles were too large to mount 4 of, so I designed and 3D printed my own in resin, modeling them to fit the curve of the wing and dialing it in through trial and error.

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I designed them with 1mm thick walls, printed in Anycubic's ABS-Like resin, each one weighing ~10g counting both peices. All 4 nacelles or all 4 front covers fit on the print bed of my Photon Zero. Final versions were printed in grey, I just happened to have white in the vat and knew I needed to prototype a few anyway.

I added tabs to the final versions which slot into the wings and are glued in for a very snug fit:
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The entire power system is borrowed from quadcopter tech - A 4-in-1 ESC, the props were a quadcopter set, and the motors are used pulls from some unknown model of drone. (makes me wonder... post drone show motors? maybe they replace entire fleets at a time)
I bought 5 motors to have a backup and sure enough 1 of them overheated during testing while the others ran fine, pulling 2.3A on 2s, producing ~100g of thrust, and ~200g of thrust on 3S, drawing 3.7A - pretty close to prop calc's numbers, current draw actually lower than expected. Those were the individual motor tests, I'll do a whole-system power and thrust test soon.

This means it should run on anything from a 2s 800mah to a 3s 2200mah, which I will test shortly.

Mounting 4-blade props was one of the goals I had in mind selecting motors. There's not many options in that size range, but I found some 5x4x4's sold as a quadcopter set that seemed promising.

I found some 1200kv motors on AliExpress that only weighed 21g, this was a breakthrough - I really like small motors with low kv's, they can turn surprisingly big propellers for more realistic proportions.

Since wiring up 4 ESC's would have been a nightmare of wires in an already cramped space, I went with a 4-in-1 ESC intended for a quadcopter, but since that lacks a BEC, I soldered on a little 5V/3A converter directly to the voltage inputs to turn it into a "fixed-wing" style ESC.
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I tied together all 4 throttle lines, and together with the BEC, I had a standard servo lead for my receiver.
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To change settings on the 4-in-1 ESC to more closely match a fixed wing's behavior, I had to buy a little flight controller to use "pass-through" because I couldn't get any of the serial protocols to connect directly to the ESC or via intermediate programmer. I raised the demag compensation and set a delay on the throttle to avoid hard stops when I throttled down, which I noticed was an issue with the stock configuration.

I 3D printed little platforms with more tabs on the bottom that glued into slots in the wing, one with screw posts for the ESC, one with zip-tie holes for the receiver, not yet attached in this pic:
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There's 12 wires tucked into each "trench" in the wings - 2x sets of motor leads and 2x servo cables for the flaps and ailerons.

to be con't...
 
some details about the paint - I used a $40 airbrush/mini compressor that did an impressive job for the price.

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I used Createx "Wicked Grey" airbrush paint. I had to experiment to find a good thinner mix to paint Styrofoam, I tried their brand name "4011" thinner but it beaded up into droplets on the foam. I found a 1:4 ratio of acetone to rubbing alcohol to make my own thinner, mixed in a 1:3 ratio to the paint worked well for smooth even coats. A 2oz bottle was enough to do 3 coats of paint:

before:
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1st coat,
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almost more like a primer, if I went too heavy it would bead up, but subsequent coats could go on thicker without trouble.

2nd coat:
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3rd:
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All from a single 2oz bottle of paint, including my clumsy learning process and mixing experiments.
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Shaking the paint and thinner in the bottle produced the best results, I cleaned & kept the empty bottle and will use it in the future as a mixing vessel, it even has a marble.

I weighed one of my mixing cups empty, wet, and dry, to figure out the final weight of the paint, and it lost more than half its weight drying- I'd estimate that about 45% of the pre-thinned weight remains as dry paint, so about 25g of weight.
 
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Thanks! I tried making the wording a bit better, you're right that it was awkward.
I thought it was me! 🤷‍♀️
Reread and yes, thats what I got from the first, second, third and... read. 🤣

I still stand by it! This really is a beautiful looking plane! 😍👍
 
Awesome, I was just starting to build this and thinking about going the 4-in-1 ESC route, so thanks for adding the info.
I’m about to order the electronics and was wondering what propeller adapters you ended up using for the motors.
Is there any chance you could post the STL files for the pods? I was literally going to start drawing them - it always blows me away someone else in the world is working on an identical project and doing it the same way haha.
Looking forward to seeing how it goes.
 
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Awesome, I was just starting to build this and thinking about going the 4-in-1 ESC route, so thanks for adding the info.
I’m about to order the electronics and was wondering what propeller adapters you ended up using for the motors.
Is there any chance you could post the STL files for the pods? I was literally going to start drawing them - it always blows me away someone else in the world is working on an identical project and doing it the same way haha.
Looking forward to seeing how it goes.

Happy to share, here they are - I'm not even the first to 3D print my own 4-engine solution, I saw another forum post doing something similar, can't find it now.

I designed them around a pretty specific motor. If you go with them then I'd buy 1 or 2 extra in case you get a dud like I did, they're cheap enough.

I'm not sure how easy the STL's will be to apply to other motors, but you could still get something from them if you DIY them.

I gave it a test flight today, it took off 2S, but it was a bit gusty out and before I could get it trimmed out it got flipped around and stalled, splitting the front halves at the seams, but the sections themselves didn't crack, the C-130's big nose makes a good bumper. Next time I'll try 3S and think the extra weight and power will help.

The CG came out just about right on mine, but I think if you turned the front section into a battery compartment you'd be fine, maybe even better off. Just a thought. I think I saw someone else do that with theirs while researching mine, there's forums posts about these from 2004 - that one has a fantastic paint job.
 
Awesome, thanks for that file. Before the accident what did the power feel like? I'll order identical gear. I'm painting it in the local AF scheme - grey like yours, nice and easy.
 
Awesome, thanks for that file. Before the accident what did the power feel like? I'll order identical gear. I'm painting it in the local AF scheme - grey like yours, nice and easy.

It took off from stubbly grass and gained altitude pretty easily, but definitely could have used more power to get out of trouble.

I was at a small local park-field so part of the issue is that I ran out of room and had to try and turn rather sharply, instead of just letting it soar for a while in whatever direction it went while keeping it airborne.

I originally designed it for a 2200mah 3S and that would bring it to 700g, but that would take it from a ~0.6 thrust to weight ratio to over 1.1. I just wanted to see if it would have more "scale" characteristics on 2S, and it definitely did, but that includes limited recovery abilities...
 
I had to do some careful foam carving to fit a 2200mah 3S, and add flaps servos:

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Nice, ill post some pics in a couple of weeks when all the parts arrive on the slow boat from China.
 
Ok, here’s where I’m at, nothing is glued yet, but all the surfaces are cut and hinged. I’m just planning out the servos now. Tudordewolf’s nacelles are perfect. I’ve added some vinyl for the colour scheme because I wanted to keep it fairly light, and I struggle to see grey models, even though I’d love to do that scheme as my airforce have grey, grey or grey haha.
I’m just waiting on some props to work out the spacing, and a few more servos. I ordered 9g, but I think I’ll go with 5g in the wings as the 9g seem too big.
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