Internal structure of RV-6A which is being constructed

Design Analysis and Construction of an RV-6A Aircraft

Since the inception of this project in 1996, 18 Honours students have participated in both theoretical analyses and hands-on construction of the RV-6A aircraft during their final year in the Department of Mechanical & Materials Engineering. They undertook this project due to their particular interest and fascination in aircrafts.

The aircraft being constructed is a high performance two seater, side by side, aircraft. It is expected to achieve a top speed of 170 kts with the cruising speed of 165 kts at 75 % power at 8000 ft. It has a short takeoff distance of about 300 ft. and landing distance of 500 ft. It has two fuel tanks, one on each wing, capable of supporting a range of about 1,400 kms. A certified Lycoming engine of 160 horsepower will be installed as the power plant.

Each year, we have a new team of students (3 or 4 in a team) working on this project. Most of them had no prior experience with aircraft construction techniques. After initial training and lots of practices on scrap materials, they gained confidence as they progressed along the construction phase. Towards the end of the academic year, they are all very competent in their workmanship. However, that is also the time they depart and a new group of students would continue with the project. The "start and stop" is not ideal for aircraft construction. However, it has been a great educational experience for the students concerned. To comply with the Airworthiness Certification requirements, at each stage of construction, it is inspected and signed off by a Technical Counsellor from the Ansett Maintenance.

The students also produced computer models of the aircraft for both finite element stress analysis and aerodynamic investigations. This exercise helps the students appreciate the basic analysis tools used in the aviation industry. For example, a weakness in the original design of the front landing gear leg was identified during the course of their analysis and the original design will be modified for extra safety.

At this moment, the tail section and two wings have been completed. The students are half way on the fuselage. The project is expected to take a few more years before completion. Judging from the log book, all the students involved have spent many hundred happy hours shaping the materials, drilling, riveting and they all proudly gave their contribution to this exciting project.