DarkAero 1 Progress Update (Feb 2021)

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It’s been a little while since our last DarkAero 1 build update video. We have a lot of footage we’ve collected over the last few weeks and there was just too much to put into one video so we highlighted three recent projects.
1) Keegan gives an overview of the carbon fiber nose gear doors. We had to finalize the CAD design details, create a mold, create some carbon fiber infused parts and get the doors all fit up and functioning. In addition to getting the doors installed we also captured the build instruction notes along with some improvements for production. Once we finish up with parts, we always document their final weight.
2) Ryley provides a brief overview of his work finishing up the battery box package. This was a bit of an iterative process as we had mocked up a 2 battery install previously. Ultimately, builders will be able to decide which setup they would like depending on their mission. The battery box is a neat little package that serves the function of not only housing the battery but also actively cooling it along with providing a mounting location for the capacitor, battery regulator and fuses.
3) River covers some of his work with the control panel. He recently got it powered on and ran a series of bench tests. In the video he gives a fun demo showing how the Garmin G3X display is communicating with the rest of the systems on the aircraft.
Intro - 00:00
Nose Gear Doors - 00:43
Battery Box - 04:40
Instrument Panel - 07:39
Other Projects - 10:32
If you enjoyed this video and would like to see more of this type of content, follow along as we work to create the fastest, longest range aircraft you can build in your garage!
More information on DarkAero can be found on our website and other social media accounts:
www.darkaero.com
/ darkaeroinc
/ darkaero-inc

[@ovenking4481]

These guys are legit. They make it sound as if it’s a simple thing. Even though they have a cnc, getting things to fit is hard, even on flat surfaces. It’s not even simple to make a decent bag and get the resin to go where you want in an infusion. It’s very expensive to learn as your destroying so much material. Respect. Excellent work from these men. Dudes like this built the world.

[@Max-re5vg]

Man ...you are so right

[@feedingravens]

Then best ask RC glider pilots, they do that on just a smaller scale and solved it. Especially the Dynamic Soaring guys know what they do, the latest speed record is 548 mph and you are pulling a constant 50g or more.

[@spdcrzy]

​@@feedingravensbut gliders are different. These guys are buildings an experimental craft, yes, but they're trying to do everything to better-than-modern levels compared to today's fully rated aircraft. So they're basically pushing the envelope as far into the future as possible. And Hill is doing the same thing for helicopters, too. It's incredible. Once wages catch up in a couple decades, these will be the new Cessna 172s.

[@philgooddr.7850]

Thank you for the update. You workmanship quality is just amazing and I wish you all the best.

[@spmckendry]

The thought processes and attention to detail you guys are going to is why you’ll be extremely successful. It’s been great to be able to watch the design come together.

[@christopherbeddoe406]

Can't wait to see Dark Arrow fly. Looks very slick.

[@JoaoBarbosa1996]

"My hobby is playing video games. What's yours?" "Oh normal boring stuff, I build airplanes"

[@spikesmth]

So awesome. Before he passed away, I helped my grandfather with an experimental plane design he was working. Same vacuum tooling. We were doing fiberglass foam core sandwiches for curved top and leading edge components. Great work!

[@XRP747E]

You guys are amazing! I have never had a brother, but a family like yours would have been great. You'll conquer the world. Thank you.

[@AJ-zj4ml]

Your knowledge of composite manufacturing methods and innovation in the design of this airframe are truly impressive. Keep up the great work!

[@vincentsimon4037]

3 brilliant minds! The Brain Brother's! Awesome plane gentlemen! Blessings and success to you all!

[@n176ldesperanza7]

A 750 pound empty weight is insanely light. You guys are doing an absolutely amazing job. I built an RV-6A so I can really appreciate what you are doing here.

[@gordonlawrence1448]

I'm a design engineer (electronics). I think you have dropped the ball with regard to the electrolytic on the front of the Lithium pack housing. As a rule of thumb a 20C rise in temperature reduces electrolytic life by a factor of 10. That could be partially mitigated by moving it towards the plenum. Another alternative is using a PCB loaded with ceramic capacitors but that will make you go cross eyed cost wise and then there is the vibration issue (they tend to crack and short out). My suggestion though is a small bank of say 20 lower value caps with radial leads on a PCB and secured with ty-wraps of the highest temp rating vs life rating you can get and and cooling them in the same housing as the lithium cells. The other point is that with lithium's there is a dendrite issue. This too can be mitigated to a point. Cooling is a damn good start. However there are military studies that demonstrate that to maximise life you need to do two things. Charge and discharge currents lower than maximum rated. The lower the current compared to maximum rated the longer they last. 2 reduce Vmax and increase Vmin on the pack. I have got a pack cycling three times a day and it's still not down to 90% capacity after 3 years by increasing Vmin to 2.8V Vmax to 4.0V and 30% of rated currents. www.powerelectronics.com/markets/mobile/article/21859861/proper-care-extends-liion-battery-life is a commerical investigation but will give you enough info to work with. Reply if you want more info. Just for the record I have been a senior design engineer for a military subcontractor, a while after that worked for Crane Aerospace, and my specialty is safety critical/high reliability systems. I also design some of the weirder instrumentation for radio telescopes (believe it or not the two fields overlap a lot).

[@dekonfrost7]

Well said.

[@_John_P]

What's a "design engineer (electronics)" and how it differs from an electronics engineer?

[@stefant6258]

Well done , I am totally fascinated by your amazing skills. I wish you the very best for your futures.

[@Chris-hall9080]

Incredible! I just started watching you guys and let me say, I am impressed! There is obviously a lot of work and dedication that has gone into this! Keep up the great work boys!

[@x10mark24]

I just find it really cool that you guys are working together as a family. my sister and I are super close and I always think its sad when people go totally separate ways when they reach adulthood

[@floodingchen]

From a former UW-Madison ME student, best wishes and good luck!

[@billmeldrum2509]

Fantastic project. Thanks for taking the time to share this with the world. 🇨🇦

[@chrisfarb]

Coolest project ever! What a great team and workspace.

[@morkovija]

Like an apple iPhone presentation with different team members covering their areas of work. High quality presentation!

[@mezo72271]

Wow guys, you are so young for so much knowledge. I think I'm the same age as you two, I completely restored a car by myself, tearing the car down to bare shell, paint it, rebuilt the engine, made custom parts, refurbished the suspension, made partly the wiring myself, and all this knowledge took at least 4-5 years. You are on a whole another level. Making carbon fiber parts, cnc machining, custom harness with circular connectors, an engine bay with such beautiful parts and a GODDAMN PLANE. Did you work on cars before or built them? Huge respect to you guys, amazing knowledge

[@MichaelNelsonYT]

I am but a High Schooler, and I have wanted to fly for a long time. This is something that has interested me a lot, I wouldn't be shocked if I were flying one of these in the next few years. Great work!

[@stachepilot5863]

Love the craftsmanship on this plane, very clean! Can’t wait to see you guys at some airshows!! Keep up the videos and hard work.

[@DarkAeroInc]

Thank you! We are excited to show the airplane off at some airshows! :)

[@casual_time_machine6536]

I'm studying to be an A&P, I love this. It really helps visualize what we're learning.

[@joseloco8186]

Looks very fast, even without wings! congrats a total beauty, can´t wait to see in flight!

[@ajussiwannabe]

I will never afford one but wishing you guys all the luck and success in this endeavor!

[@rudidup]

The workshop is so tidy and the build is so neat. This is awesome!

[@customafd248]

Awesome, always in hopes to see the next videos. Keep the content coming!

[@lorenzocano7884]

Guys, your is not an aircraft shop, it is a neurosurgery operating room, all is always perfect, clean, clear, a real joy of the mind, all looks the best possible solution, deeply considered, thought, analyzed. Dark Aero is essentially a mental status of coherence and beauty.

[@Tubefish07]

I can’t and won’t try to speak for anyone else but I’m ready to risk my life on these hypotheses! Brilliant! Cheers mates!!

[@jeffabernathy3131]

Amazing work. Glad I stumbled across your feed. I will continue watching as your aircraft appears to be pretty awesome, even if it isn't flying - yet.

[@jetrep]

You guys are really doing some beautiful work.

[@Dr_Kenneth_Noisewater]

Just found your channel (what took so long, algorithm?). I love what you guys are doing and that you’re sharing it. Aerospace, mechanical and electrical engineers. It’s like you guys went to college with an aircraft company in mind. Best of luck to you and your company!

[@superstraightflyer]

Amazing project and talent, I have good feeling this going to be a winner!

[@jean-pierrelenormand1730]

Thank you for making such professional quality videos and explaining everything as you do so. recently found your Chanel and have subscribed and watched lots of your content. Keep it up.

[@ubersosiska]

Guys, it`s so cool stuff you make. Great job!

[@ogplboogiemangonzo7129]

Hey guys it's looks as it's coming rite along . Great work Looks awsum .👌👌👌👌

[@kuri369kuri]

Popped up on my feed out of the blue. Cool project boys. I’ll pay this ticket and see this thing through.

[@mustanggun]

I'm a backcountry guy, but your new plane makes me want to go fast. Love your work

[@PatHaskell]

Very impressive. Nice to see someone actually building something.

[@johnroddy8756]

Amazing,work shop,aircraft and knowledge you guys have.Well done it will be great.

[@shawn3744]

am i the only one who want to see these guys work with mike patey to see how crazy this build can get . great job guys im here for it all

[@AeroworksProductions]

Looks like they’re doing just fine by themselves.

[@999Muskrats]

I have asked a similar question. They both have such different approaches. I would love to hear/see a compare and contrast. Perhaps they will do a panel discussion at AirVentures this summer with DA1 and Scrappy on stage.

[@eugenejulson8742]

I was wondering if they are trying to beat Mike’s Turbulence. ??

[@shawnrhatigan06061]

@@999Muskrats They are building the fastest, most fuel efficient, easiest to build kit airplane. Mike Patey is making the perfect STOL airplane with EVERY feature HE wants when HE goes flying.

[@leighphillips6782]

Gorgeous Plane gents’. I’m currently building an RV-12is.I think when I’m ready for a speed and distance upgrade I’ll be calling you boys up for a test flight. Keep up the good work!

[@RomanKozlov007]

You guys are great - don't you ever give up! Blessings!

I always amazed with the amount of materials spent on transverse frames for non pressurised fuselages instead of care about "bridge" bending loads.

[@hello_world_zz]

guys you do fantastic work!

[@bflo2564]

Keep the videos coming guys! Always a joy to watch.

[@ScottsSynthStuff]

I just realized that every time you post a video, it seems like I write critiques or questions about specific items. Most of the time your answer is "yes, we thought of that, and here's how we're dealing with it." To be sure, I am not criticizing the build or the project, I think it is a fabulous project and I am in awe of the level of quality engineering being applied. I do tend to look for failure points in things, so if I do see something, I tend to say something. :)

[@DarkAeroInc]

Hey Scott thank you for the extra scrutiny! :) No harm in voicing concerns to improve a design. Lol you should see the some of our design reviews. XD We rip apart ideas pretty ruthlessly. Certainly it's nice when it's just the "already thought of that" type questions but it helps us out when viewers with watchful eyes expose blind spots in our work as well.

[@derekevans7829]

You guys are crushing the game and breathing new life into the experimental arena!! Keep it up! 💪🏾💪🏾

[@markdoan1472]

Uhmm ... its nothing until it flies .. just a collection of design build videos . I will only be impressed when the 20'th kit is sold and out the door

[@derekevans7829]

@@markdoan1472 No matter what you do, there’s always going to be haters in the crowd. Lol. Instead of getting on here and throwing out negative energy, why don’t you try to help out? Are you able to provide some useful insight or help? They are doing some pretty amazing stuff not only an engineering standpoint, but also for the aviation community as a whole. Looking forward to the first flight DA!!

[@markdoan1472]

@@derekevans7829 My issue is the aircraft industry has been plagued with over sell and under deliver fly by night operators for decades ... more often than not asking for deposits and 15 years later you wonder what happened to the deposit ... Note how these kids dont have a flying model yet but have a company name and lots of hype , videos etc ... How many times have we seen this ... Perhaps you have not been paying attention ... The only thing that impresses me is results ... There have been countless builds gone way further than this ... I have built and sold quite a few products in the RC industry ..( tuned exhaust , fuel systems ) Never once hyped anything until it was painted , boxed and ready for a credit card ..... These boys been at it for a while and have made only modest progress ... Nothing impresses me until production runs are sold

[@shawnrhatigan06061]

@@markdoan1472 I understand your doubt. Most of us aviation folk can remember the Moller Aircar. But these guys have broken thru a lot of known hurdles. They are a couple yrs behind target, but COVID crap has slowed everything down. Check out their design of no ribs. See how they have been perfecting the infusion process of resin into the carbon fiber. Their honeycomb sandwich of carbon fiber has been a major breakthrough and is still being perfected for the production aircraft. They are putting everything out there to educate, and to raise awareness, and to get help with anything they may have missed. They are the real deal. Maybe no one will end up buying this aircraft, but I HIGHLY doubt it.

[@hectorherbert6585]

One great little tools are laptop 12V cooling fans ,they are cheap ,very light ,reliable and efficient ,when I built my sleeper Volvo carbon fiber dashboard ,I used them at key spots to keep my fuse boxes ,wiring ,gauges ,battery packs always ventilated and to extract hot air in tight closed spaces ,and it fights humidity too in critical places.

[@darnation8650]

Always enjoy seeing your progress.

[@jimmyoverly3512]

Love your progress! Keep on keepin' on!

[@kavorka8855]

Awesome brothers! Wish you all the veeeeeeeeeeeeeeery best!

[@bogwojny4740]

FANTASTIC WORK

[@cammo4000]

Impressive progress! Well done.

[@Skinflaps_Meatslapper]

The battery cooling duct might be a problem after shutdown. I've had similar issues with my RV8 when testing battery box temps for my new lithium battery, and just barely caught the temp rise after sitting in the cockpit with the master on while making a few notes. The cooling plenum is raised above the inlet, so the hotter air from the cylinders will naturally want to rise and be trapped up top in that space, potentially allowing hot air to migrate through the SCAT tubing into the battery box. Only thing I can think of to remedy that if it becomes a problem is to route the tubing straight to the inlet away from the plenum above the cylinders, or build the tubing from sheetmetal integral to the plenum wall itself with an opening close to the inlet. Probably not a great idea to vent it directly to the cowling, and adding a NACA duct or similar to the cowling just complicates things with additional weight/drag/cowling removal. I elected to bond carbon fiber tubing alongside the plenum (which was also CF) and simply trimmed an inlet for it near the cowling inlet after molding a simple duct to connect fresh air with the battery, which solved the problem. The battery stays a few degrees above ambient even during summer temps in TX.

[@AUS5113]

Now that I have seen the aircraft being handled by you guys it look so small. I am sure it will be fun fly once it is complete. It looks amazingly lite.

[@plumbum6777]

I love the way to work, so i finde your Projekt is very clear und beautyful. Compliments from a German Master of Mechanik. Go the way forfard. This Airplan Is the best i've seen since the ultalight Faszination from Germany

[@alexanderarnett4966]

Superb work as usual. River, it looks like your still using standard nylon lock ties, have you considered using GripLockTies on the wiring harness? These could all but eliminate the long term problem of wire insulation chafing and wear through as a points of failure. Tracking down that insidious intermittent ground hum on comms or the tripped circuit breaker that only seems to happen when your midway through your flight is always a pain but a complete failure in one of the critical electronic signal, comms or electrical control systems could be real bad. Gone are the days when it’s a good day if you can walk away from a gear up landing, because the economics of Experimental Aircraft operations and its insurance implications often mean that you end up also walking away from your flying career as well. Much worse would be electrical arc causing smoke in the cabin or an engine fire could if it were to result in the loss of the aircraft and just catastrophic if were to result the loss of pilot and passenger. As engineers we can never escape these two words, ‘Risk Mitigation.’

[@bj-th7ul]

It doesn't mean much but I'm impressed... with nearly 30 years in (CAD/CAM) aerospace composite part manufacturing (and as a private pilot - 45 yrs... which also never seemed to mean much to anyone other than me) it's interesting to see what you're doing. There are times that I think I'd like to have been involved with projects like this. Building an airplane is not a simple project. Thanks for sharing, stay safe, enjoy

[@mattmoore1882]

glad to see those sweet carbon fiber ailerons , sick

[@yeboscrebo4451]

Wow! Inspiring. Good luck you guys

[@hgutierr]

Great job!!! Thanks for sharing your progress.

[@karlwilliams8208]

Amazing, keep up the excellent work 👍🏻

[@raoulroyackers9391]

That fuselage looks sick.

[@wesvasher]

Amazing job guys.

[@robertely686]

Awesome. Thanks for the ideas!

[@Heico321]

Great video! I really enjoy watching you progress. 😊 Not sure if you already covered the topic, but I'd be very interested in how you guys handle the different thermal expansion of carbon fibre and the other materials (especially aluminium).

[@daralaujam]

Great job mate 🤞🤞🤞

[@williamreymond2669]

What has always impressed, and troubled me, about landing gear doors is the tremendous aerodynamic loads they must endure, over many take-off and landing cycles. You never open your car doors at 200mph, or just remember to shut them when you are going 150mph. But that is normal for an aircraft. Remember those old Volkswager TV commercials from the 1970's - no you don't you are too young. You do remember TV at least? Well, some well-paid-presenter would walk around the Beetle opening and closing doors with a satisfying 'thunk!' As it turns out, the actual sounds of the actual VW Beetle's doors opening and closing were replaced with previously recorded sounds of a Rolls Royce's doors being opened and closed. Those itty little landing gear doors yours actually sound pretty solid.

[@tezlashock]

good to see that the hinges mount to the support structure

[@pietervisser7683]

Awesome job, love following you progress and of course can't wait to see it leave terra firma! Keep it up.

[@puddleglum90]

Thanks for the update!

[@chaddonschaddons7084]

5:50, a small tip on improvement is to make the airflow duct - feed the bottom of the battery can and vent the outflow of that air on the top side of the battery can.

[@ErionElPintor]

Looking great! On Wisconsin!

[@NewajAhmed1]

Can't wait to see complete aircraft ❤❤❤

[@MrDrago1954]

You guys do good work. Keep it up.

[@GaryL3803]

Seeing the battery forced air ventilation I wonder how a battery cold at altitude would react to condensing moisture when descending through clouds and precipitation.

[@gamalibrahim394]

Wonderful work.

[@sanpol4399]

Beautiful machine.

[@ColinWatters]

Looks great.

[@rynokruger1227]

Super cool guys, LIKE THIS ! Keep it up cheers

[@Scrogan]

CNC MDF for CFRP moulds? That’s what I’ve always thought would be a quick method for composite prototyping. Don’t know how I’ve missed this channel until now, great quality project here.

[@evilfish456]

This is kind of like discovering Project binky. Haha quess I will be spending this day by watching whole channel trough

[@lenz2955]

Watch out Mike Patey! (any patey fans here?) Nice work boys!

[@Daytonaman675]

Patey fan - these guys are not QUITE on the same “big boy toys” level as mike but also are much younger. Gonna be cool watching what they are able to do

[@lenz2955]

@@Daytonaman675 How true.

[@Idlecodex]

What an exciting project! I feel a bit of jealousy! ;) Seriously, I wish you guys I'll the success in your venture, both the engineering and the business, so you can keep on building the stuff you like as you like!

[@user-xl3yd4bp9d]

It is great! Very nice worrk!

[@boomerhgt]

Very interesting videos these guys have skills awesome looking project subbed and liked and hi from Scotland

[@benbel8177]

I will be definitely one of your first customers. I really love this project and your way of thinking . I juste received your email , with the Carlos Z design of the cockpit (avionics) I have some suggestions below: - add AOA ( Angle Of Attack) just above the PFD One of the mnemonic I always remember when I fly IFR is “TUPS” (Time Undercarriage Power and Switches) So if you - add a clock above the PFD between AOA and undercarriage switch - (and I know, flaps switches are most of the time near the power throttle) but I think flaps switch should be near undercarriage switch as well. So it would be the perfect UX for an IFR flight especially for the approach phase of the flight . Gear up -> flaps up Gear down -> flaps down

[@83aceman]

Awesome aircraft.

[@claude7473]

Great American engineers at work !!!

[@astrazenica7783]

Sweet lines on that bad boy

[@RalphReagan]

So beautiful!!!!

[@polar_engineering]

Literally a dream job!

[@emreyavuz8246]

I’d love to work for you guys!! Can’t wait to see it flying!!

[@h-j.k.8971]

Probably keeps you out of mischief ;-) no but seriously, great project and nicely documented. Definately Thumbs up on this.

[@Barskor1]

If the availability increases and the cost of graphene flakes come down low enough you might consider adding them to your resins for greater strength. I love this craft!

[@DanaKotze]

Good luck👍

[@yuriykhylchuk4308]

Nice job!

[@daddylong69]

You could make the door be rotated into the hole and out of it kind of like a conveyor belt that goes one way and back the other but using a small hydrolic puller to get the door to move underneath. That way you only have to make one piece instead of three.

[@tariqghuman]

What a beauty 😍

[@feedingravens]

On the deHavilland Mosquito the gear door mechanism was astonishingly crude: tube "skids" on the strut pushed open the doors at the front, and they were closed by coil springs at the back. Caused no problem at 350 mph. I do not think they even had a locking mechanism. Of course one would build that of carbon today. As closing spring I could imagine a LENGTHwise flat strip that is twisted 90 degrees when opening.