Chuck and Ryan's Build Tips

[ceslaw]

Rear Seat, Part I. The Carbon Cub comes with a sling seat for the rear passenger however a more substantial seat that matched the front was our preference. Both Cub Crafters and Acme Aero sell a rear seat for a king’s ransom, so we opted to build our own.

Goals included making the seat easily removable and matching the geometry of the front seat as close as possible. The design needed to utilize the cross brace which is the attachment point for the sling seat since it is tied directly into the frame.

A wooden mockup was made to determine the primary dimensions. This was used to confirm the location of the attachment points, to match the angle of the front seat using a digital level, and also the best height in the available space. The seat was temporarily set on this wooden frame for a “test sit.”

IMG_1752.jpg

Patterns for the side pieces were created and tested in place to confirm the dimensions.

IMG_1667 (2).jpg

Steel rather than aluminum was used, which was ordered from McMaster Carr. It is shocking how much steel prices have jumped in the last year.

The primary shape of the 3” high side pieces were cut with a jig saw and then the mill was used to drill all the holes. The mill assured precise positioning.

IMG_1679 (2).jpg

Once the primary pieces were cut, they were tack welded together and the dimensions and location reconfirmed.

IMG_1683.jpg

[lbell]

Rear Seat, Part I. The Carbon Cub comes with a sling seat for the rear passenger however a more substantial seat that matched the front was our preference. Both Cub Crafters and Acme Aero sell a rear seat for a king’s ransom, so we opted to build our own.

Goals included making the seat easily removable and matching the geometry of the front seat as close as possible. The design needed to utilize the cross brace which is the attachment point for the sling seat since it is tied directly into the frame.

A wooden mockup was made to determine the primary dimensions. This was used to confirm the location of the attachment points, to match the angle of the front seat using a digital level, and also the best height in the available space. The seat was temporarily set on this wooden frame for a “test sit.”

IMG_1752.jpg

Patterns for the side pieces were created and tested in place to confirm the dimensions.

IMG_1667 (2).jpg

Steel rather than aluminum was used, which was ordered from McMaster Carr. It is shocking how much steel prices have jumped in the last year.

The primary shape of the 3” high side pieces were cut with a jig saw and then the mill was used to drill all the holes. The mill assured precise positioning.

IMG_1679 (2).jpg

Once the primary pieces were cut, they were tack welded together and the dimensions and location reconfirmed.

IMG_1683.jpg

Looks like a perfect job for laser or water jet if you make a cad file.

[aeroaddict]

Very nice. Can't wait to see the final configuration!

You are not going to use the (stupid) pins for seat postion are you?

[Daveembry]

This is great! Maybe the start of something new! Ryan O’Toole started making the Headset “brains” several years ago and they have been a great hit. https://www.raoideas.com/

Maybe sell these???

Rear Seat, Part I. The Carbon Cub comes with a sling seat for the rear passenger however a more substantial seat that matched the front was our preference. Both Cub Crafters and Acme Aero sell a rear seat for a king’s ransom, so we opted to build our own.

Goals included making the seat easily removable and matching the geometry of the front seat as close as possible. The design needed to utilize the cross brace which is the attachment point for the sling seat since it is tied directly into the frame.

A wooden mockup was made to determine the primary dimensions. This was used to confirm the location of the attachment points, to match the angle of the front seat using a digital level, and also the best height in the available space. The seat was temporarily set on this wooden frame for a “test sit.”

IMG_1752.jpg

Patterns for the side pieces were created and tested in place to confirm the dimensions.

IMG_1667 (2).jpg

Steel rather than aluminum was used, which was ordered from McMaster Carr. It is shocking how much steel prices have jumped in the last year.

The primary shape of the 3” high side pieces were cut with a jig saw and then the mill was used to drill all the holes. The mill assured precise positioning.

IMG_1679 (2).jpg

Once the primary pieces were cut, they were tack welded together and the dimensions and location reconfirmed.

IMG_1683.jpg

[ceslaw]

Looks like a perfect job for laser or water jet if you make a cad file.

You nailed that one. if only I were CAD capable and had a laser/water jet. Could have done in minutes what took days.

[ceslaw]

This is great! Maybe the start of something new! Ryan O’Toole started making the Headset “brains” several years ago and they have been a great hit. https://www.raoideas.com/

Maybe sell these???

Need to produce it with CAD / jetting to make that feasible.

[ceslaw]

Very nice. Can't wait to see the final configuration!

You are not going to use the (stupid) pins for seat postion are you?

Nope. Not on a back seat. But the holes will be there regardless.

[lbell]

Need to produce it with CAD / jetting to make that feasible.

There are ways to scan the parts and convert to cad

[ceslaw]

There are ways to scan the parts and convert to cad

if I build another that is an option that definitely needs to be pursued.

[ceslaw]

Rear Seat Part II. The rear seat frame support is a one-inch square tube tied to the frame at the outward seat belt bolt locations. The seat belts will later be placed in their normal location under the tube. Socket head bolts were used with a larger hole on the top of the tube to provide access. This rear support is primarily to carry the weight and center the seat laterally. The forward tube will carry the primary fore and aft forces.

The tack welded frame was set in place to confirm the fit. The notch at the base of the frame set in place perfectly and the incline angle of the top matched the front seat.

After conferring with Ryan, my resident engineer, it was determined that a top section was needed to improve the overall rigidity of the ‘box’. Cutting the lightening holes proved to be an all-day job, including 26 one-inch diameter holes which became the corners of the lightening holes. The mill proved very helpful in assuring precise location of the holes.

IMG_1725.jpg

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A vertical cross piece was also added near the center for additional support.

65160147748__884A0C95-BC40-4289-BE8F-17EB9F4D8F45.jpg

These sections were tack welded in place. The basic frame is now nearly complete

IMG_1776.jpg