Most important aspect of the design was to ensure that kids fit into the plane. The only way I can ensure that happens is to get a profile view of the target audience. Fortunately my two kids are ages 6 and 9 so this works perfect. I had them pose in a sitting position and then took pictures. I was then able to transfer their outlines into AutoCAD and then I can begin the task of drawings the aircraft around them.
Now that I had the right profile, I could then work out the scale and geometry of the aircraft
Now came the very long and difficult process to turn the 2D sketches into a 3D design. After about 3 weeks of work the design began to take shape. I design the pieces similar to how the wood dinosaur puzzles go together. Just an assortment of 2D shapes that fit together to make a 3D piece.
Once I was satisfied with the design, I had to ensure that it was actually going to work. Often when designing in 2 dimensions its hard to determine how things will fit together until you actually begin to build. The easiest way I could verify the design was to digitally build the aircraft. It only took about a weeks worth of time to transform the design into 3D. With a few modifications to the design, I could prove that it will work and look great.
My father used to paint signs when I was young. I remember the technique he used, drawing the designs in pencil, and then tracing them onto the boards and hand painting everything. I still have some of his tools. In particular the pounce wheel. This was a common tool/method used to transfer designs from large pieces of paper onto virtually any media.
The pounce wheel has small spikes on it that perforate the paper. Once all of the lines are traced out with the perforations, chalk is tapped over the paper and the outline is left behind. I printed an outline of each piece on the plotter and then spent the time tracing it all with the wheel.
Using black carpenters chalk, I transferred the pieces to the plywood.
I now have a perfect outline to work from.
The first two pieces are cut and ready for final shaping. Fortunately I had lots of help from everyone at the Edmonton Homebuilt Aircraft Association and EAA Chapter 30. Lots and lots of hours when into cutting all of the pieces and shaping them.
After a couple of weeks we managed to have nearly all the pieces rough-cut and ready for assembly.
I soon realized that working only Monday evenings with the group, we would never reach the deadline. So I took the project home and began assembling. One of the items that I really wanted was a cool bolstered seat. I wanted the cockpit to be like a race car. So it would really stick out in their minds. I began working away on a wood seat. Mostly because I couldn't seem to find a kids wood seat to buy.
Assembly took an incredible amount of work. Its funny how things just slap together in your mind, but in real life. Not the case. Lots of painstaking work and measurements and router jigs were put into good use.
Once I was happy with the geometry I could advance into the more complicated pieces of fabrication.
At this point the EHAA/EAA club found some landing gear off an old homebuilt aircraft that I could use. I can tell you how much work went into getting the gear to work. I even had to consult with a structural engineer to deal with the torsional stresses that the raked gear presented.
The best part of the whole project is when folks would donate their expertise and materials. We had so many parts and labor donated - Welders, a nose cone, and the part kids really like, the instruments.
