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Cox Engine of The Month
June-2024
F4D Phantom II's

"Cox .049 Marine inboard engine."

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Roddie-Rigger.. a 2005 original design Empty Roddie-Rigger.. a 2005 original design

Post  roddie Thu Apr 25, 2024 3:39 pm

I thought-up this outrigger model boat design almost 20 years ago when I worked at the sign company. I ran CNC routers that were used to cut dimensional graphics made from foam-board (3/16" through 3" thicknesses...) balsawood, ply/hard wood, PVC, polystyrene, acrylic, aluminum.. lots of materials that lent themselves to my hobby interests. I was able to do some CAD while the machines were on long-running jobs. The outrigger was just one of quite a few CAD projects that I was able to create and cut.

Here's a CAD image of all the parts that make up the rigger-design from back then. I could "pull" parts from this file.. and cut them from the various materials listed.

Roddie-Rigger.. a 2005 original design Roddie19


I made a boxful of parts that had been in storage since then.. and I had also mocked-up a hull that's been kicking-around.. well.. for way too long.. and has workshop-rash to prove it.

Shown below; with prospective Cox .049 reed-valve engine and 2mm shaft (wire) drive. This would come together quickly at this point/stage in time.

Roddie-Rigger.. a 2005 original design 20240434


Since I've been sourcing parts for the Cox powered jet-pump.. it's rekindled my interest. I un-buried the rigger's box-o-parts and thought; "what a shame to let this keep sitting.."

Roddie-Rigger.. a 2005 original design Roddie20


Apparently I was confident in my design... because I made parts enough for several models..  Laughing

Below image is of two differing profile foam-board sponson "blanks" and .030" aluminum sanding-templates to contour the foam to form a 90 degree (right-angle) or 60 degree angle at the step.


Roddie-Rigger.. a 2005 original design Sponso10


Roddie-Rigger.. a 2005 original design Sponso11


The aluminum boom stock tubing is used to hold the templates in alignment when sanding-in the contours.


These foam parts are of the polyurethane type and need to be "faced" with something smooth and lightweight. There's no wood to worry about here.. but unprotected foam gets dinged-up with discouraging ease. I've got some options.. it just depends on the method of adhering a given skin to the foam.
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Roddie-Rigger.. a 2005 original design Empty sponsons..

Post  roddie Thu May 02, 2024 1:30 am

These .040" aluminum sanding templates work nice. It takes a little work with a sanding block and coarse paper.. but I like the outcome.


60 degree step...


Roddie-Rigger.. a 2005 original design 20240515


Roddie-Rigger.. a 2005 original design 20240522


Roddie-Rigger.. a 2005 original design 20240521


Roddie-Rigger.. a 2005 original design 20240520


Roddie-Rigger.. a 2005 original design 20240523


Roddie-Rigger.. a 2005 original design 20240524


Roddie-Rigger.. a 2005 original design 20240525


Roddie-Rigger.. a 2005 original design Sponso12
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Post  MauricioB Thu May 02, 2024 1:50 am

excellent work Rodie and as always, very organized!...it's good that you restarted those pieces that were waiting for you friend!
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Post  rsv1cox Thu May 02, 2024 6:23 am

Nice! I'm always impressed by your creative skills.

That little Cox .049 looks natural sitting in there, but what's the funnel behind/on the fuel tank?

Roddie-Rigger.. a 2005 original design Roddie13
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Post  roddie Thu May 02, 2024 12:03 pm

rsv1cox wrote:Nice!   I'm always impressed by your creative skills.  

That little Cox .049 looks natural sitting in there, but what's the funnel behind/on the fuel tank?  


Thanks Robert! That's a velocity-stack that I fitted to the choke-tube.

Roddie-Rigger.. a 2005 original design 20240439

There will be an external fuel-cell of approx. 10cc capacity.. but I'm not sure yet what type I'm going to use.
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Post  rsv1cox Thu May 02, 2024 12:17 pm

Ah......A Cox Sure-Start. I should have known.
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Post  roddie Fri May 03, 2024 2:42 pm

rsv1cox wrote:Ah......A Cox Sure-Start.  I should have known.  

Yea.. that's what it looks like.. but I don't own any Sure Start engines Robert. I mix/match various engine parts to make custom configurations. That's what makes the Cox engines (especially the .049's) so much fun to work with.

The "Rigger" engine will undoubtedly morph into different configurations through both; bench-testing and "real-world" running on the water.

I'm working on a test-stand that will use a 2L. capacity bottle of water for the cooling coil around the cylinder-head.. to see how the engine behaves with a flywheel mounted "no-load" vs. a simulated working-load.

Here's some eye-candy.. Laughing

Roddie-Rigger.. a 2005 original design Bench_10


Roddie-Rigger.. a 2005 original design Bench_11


Roddie-Rigger.. a 2005 original design Bench_12


The L-bracket on the back of the fixture is for a fuel-cell of some sort. Not sure yet; what that will be... Huh...
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Roddie-Rigger.. a 2005 original design Empty marine rudder, fins and trim-tabs

Post  roddie Fri May 03, 2024 9:51 pm

I searched and found a "rudder" on Amazon.. and for $10 (USD) got that plus turn-fins and trim-tabs in a replacement-kit for a small RC race boat that they stock. Amazon also offers through/below-the-hull rudder kits.. but those aren't what I would want to run on an outrigger hydro. Those below-the-hull rudders seem more appropriate for "scale-model" subjects.

This will work for the Roddie-Rigger..


Roddie-Rigger.. a 2005 original design Roddie32
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Roddie-Rigger.. a 2005 original design Empty getting back to the sponsons..

Post  roddie Sun May 05, 2024 10:27 pm

getting back to the sponsons.. I knew that I needed to "skin" the exposed foam sections (the tops and bottoms..) but wasn't sure what to use.. and I'm unsure about this choice.. but when you're designing something.. you just have to go with it sometimes. The exposed foam depresses/crushes easily if even slightly impacted. I thought about trying a skin of plastic "sheet-protector" material.. but it's too thin and too flexible to protect the foam. I needed a "shell" of sorts.. but not at a big weight penalty.

The bare "tub" with booms/sponsons is pretty light..


Roddie-Rigger.. a 2005 original design 20240526

Roddie-Rigger.. a 2005 original design 20240527


The sponsons are made from 1.5" "Ultraboard" a sign-grade foamboard faced both sides with .015" Polystyrene. So they're 1.5" wide.. which is what the skins need to be. The "sides" have the .015" Polystyrene facers. The Top & Bottom are exposed-foam that needs to be skinned.

I'm "going with" another sign-shop material that I had on hand.. which is .018" phenolic sheet. The sponsons measure 8.0" long on the top.. which is flat. The bottom skin needs to be longer at 8.312" because of the upward-sweep running from the step... to the up-swept front tip. I laid out skins for both; 60 & 90 degree versions. Eight strips @ 1.5" wide.


Roddie-Rigger.. a 2005 original design _018_p10


It's been coiled tightly........  Shocked ... so I need to try to flatten it out. I'm going to try weighting-down flat with books overnight.. and will check to see how/if it relaxes...


Roddie-Rigger.. a 2005 original design _018_p11







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Roddie-Rigger.. a 2005 original design Empty Steamed skins

Post  roddie Tue May 07, 2024 11:21 pm

It took steam to take the coil-temper out the .018" skin material.. but it worked.


Roddie-Rigger.. a 2005 original design _018_p12


I've got a plan for applying the skins.. but I'm using sacrificial sponsons in case it doesn't pan-out. I threw together a paint fixture which has rods that key into the two boom sockets.


Roddie-Rigger.. a 2005 original design 20240529


I foam-brushed-on KILZ2


Roddie-Rigger.. a 2005 original design 20240528


The weather here in Northern Rhode Island was superb today. I spent several mid-day hours at the markets. A husband's (retired) chores are never done...
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Post  getback Wed May 08, 2024 6:31 am

Interesting , yes the weather was nice here to today going for hot thought at 88F ! Then a cool down . If can get caught up on old man chores may spray some dope to day ?! Glad you got sometime to work on the outrigger ! Very Happy
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Post  roddie Wed May 08, 2024 7:04 pm

getback wrote:Interesting , yes the weather was nice here to today going for hot thought at 88F ! Then a cool down . If can get caught up on old man chores may spray some dope to day ?! Glad you got sometime to work on the outrigger ! Very Happy

Thanks Brother. It was good to chat with you on the telephone. I find these days; that I'm more anxious to prove things. It must show here.. in my posts. Yea.. later on that..

So.. after scratching my head bloody; searching for info. on contact-adhesives that wouldn't degrade my polystyrene foam. Shocked There's so much contradictory info. out there.

I decided to go with a Gorilla Glue product.. but it's not a liquid.

Roddie-Rigger.. a 2005 original design _018_p14

Roddie-Rigger.. a 2005 original design _018_p13


That's a "scrap" (sacrificial) foam sponson that I used for this experiment. I've used double-sided tape before.. and it works quite well for certain applications. The Gorilla variety is 1.4 inches width. My sponsons are 1.5 inches wide. Adhering the tape-strips along the top and bottom "skins" worked out well. There's room for slight misalignment with the tape-strip without going over the edge.

The Kilz2 that I foam-brushed onto the bare foam sections of the sponson was dry when I checked it 12 hours later. I feel that this application gives the d/s tape more to stick to. I'll seal the edges/seams with an acrylic caulk prior to painting. The main issue was getting the skins to "stick" instantly.. and that's working.

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Post  roddie Fri May 10, 2024 11:52 am

So I had made-up X2 sets of foam sponson cores to experiment with; one set with 60 degree angled steps.. and the other with 90 degree angled steps.

I put together a painting fixture.. and prepared X2 sets of skins with the Gorilla D/S tape.


Roddie-Rigger.. a 2005 original design Kilz2_10

Roddie-Rigger.. a 2005 original design Gorill10

Roddie-Rigger.. a 2005 original design _018_p17

The sponsons are designed to easily and quickly slide on and off the booms and are held captive by little hitch-pins. The booms consist of X2 7/32" aluminum tubes of 9.5" length, which slide-through captive 1/4" aluminum tubes in the tub and sponsons. There are also 1/4" alum. spacer-tubes that "slide-on" between the tub and sponsons. I designed the system around the 1.5" width of the sponson material.. and made the tub 3.0" wide with a 1.5" (spacer-tubes) between the tub and sponsons.. for an overall width of 9.0". The booms are 9.5" long to accommodate a flat-washer/hitch-pin retention system.

It's a lightweight arrangement that can be completely disassembled if a part gets damaged.


Roddie-Rigger.. a 2005 original design Boom-t10


Last edited by roddie on Fri May 10, 2024 5:57 pm; edited 1 time in total (Reason for editing : added a photo)
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Post  roddie Fri Jun 07, 2024 5:46 pm

I just read my last post.... and thought.... Jeeee... why would anyone else want to know that...
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Post  rsv1cox Fri Jun 07, 2024 6:35 pm

roddie wrote:I just read my last post.... and thought.... Jeeee... why would anyone else want to know that...

Smile Smile

Lot's of numbers there roddie, but some here are number people.

Jeeee... why would anyone else want to know that...

I wonder that about all my threads roddie. Smile
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Post  MauricioB Sat Jun 08, 2024 11:31 am

a lot of work there Roddie....great! Clapping Clapping
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Post  rdw777 Sat Jun 08, 2024 3:19 pm

I like the details and the numbers Roddie… Plus replaceable/adjustable modular parts….Leaves plenty of wiggle room to make it do what you want Thumbs Up
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Post  davidll1984 Sun Jun 09, 2024 8:06 am

roddie wrote:
getback wrote:Interesting , yes the weather was nice here to today going for hot thought at 88F ! Then a cool down . If can get caught up on old man chores may spray some dope to day ?! Glad you got sometime to work on the outrigger ! Very Happy

Thanks Brother. It was good to chat with you on the telephone. I find these days; that I'm more anxious to prove things. It must show here.. in my posts. Yea.. later on that..

So.. after scratching my head bloody; searching for info. on contact-adhesives that wouldn't degrade my polystyrene foam. Shocked There's so much contradictory info. out there.

I decided to go with a Gorilla Glue

I have no doubt that the glue you use is good but for the foam I use this Roddie-Rigger.. a 2005 original design 17179310
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Post  roddie Sun Jun 09, 2024 12:34 pm

Thanks Robert, Mauricio, Robert and David for your support. I've been stalled-out the last few days.. but hope to getback to it soon. I want to run this boat this Summer. (How many times have I said that about a model that I was working on.. and had it not happen..?  Embarassed )

Little by little.. I'm getting things put together.. and/or sourcing what I need to get things put together..  

I drilled/tapped 5-40/UNC some 2mm couplers to accept a 5-40 stub-shaft on the input (engine) side... and the 2mm stainless steel bike spokes for a wire-drive on the couplers' output side. It's helpful to have 5-40 tap/die in your Cox toolbox.

Roddie-Rigger.. a 2005 original design Engine15

I drilled a .063" cross-hole in one of the couplings to accept a piece of .062" music-wire as a "wrench" for tightening a 5-40 hex-nut.

Roddie-Rigger.. a 2005 original design Coupli12

Here's an alternate view of the rudder, from a kit that I sourced through Amazon. The white PVC block was something I had in my boat parts-box.. and will provide extra clearance behind the propeller. This will allow the rudder to be mounted on the center-line of the hull.

Roddie-Rigger.. a 2005 original design Rudder10

Roddie-Rigger.. a 2005 original design Rudder11


Last edited by roddie on Sun Jun 09, 2024 12:44 pm; edited 1 time in total (Reason for editing : added a photo)
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