Aluminum Dragon

Discussion in 'Member Project Logs' started by proppastie, Mar 29, 2016.

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  1. Oct 24, 2019 #181

    proppastie

    proppastie

    proppastie

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    Just in time for Halloween.....it's like a corn maze......Now I have to figure out what the next step is, with hundreds of clecos I do not want to have to take it apart and put it back together any more times than I have to.

    IMG_20191023_204730.jpg
     
  2. Nov 10, 2019 #182

    proppastie

    proppastie

    proppastie

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    borrowed RV tool for dimples in LE,....setting up 6" dihedral. Spar now has web re-installed.

    IMG_20191031_100609.jpg IMG_20191108_104122.jpg IMG_20191108_104225.jpg
     
    Joe Fisher, jmt1991 and cheapracer like this.
  3. Nov 17, 2019 #183

    proppastie

    proppastie

    proppastie

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    Finished to size 1/4 Dia. carry through bolts..... drill and ream....What a PTA ....
    Shown the center wing attach fittings and tube structure for the Fuselage, cheap Chineese drill press and oh yes ,,,broke the ream on the last hole.
    Notice the difference between drawn theroetical and actual hole location....make the caps bigger and trim later.

    Main problem was I used the wing attach fittings full size holes for stress test of the boom, and now I had to duplicate the holes without cutting/buggering into the full size holes on the fittings. Should have done it in a Mill ...indicate the hole remove the fitting and bore.....but I do not have a milling machine. I used every trick I could think of.

    bushings machined from 1/4x.035 4130 tube, 1/4 hole reamed in a 1/2 piece of steel clampped to the work, 7/32 end mill, 7/32 drill, D (.246) drill,.2500 ream, lots of assembly dissassembly.....the wood table would flex when I screwed the base of the drill press down to keep it from lifting when drilling......Now I wish I had the NC router.

    and In order to stress test only one wing I have to drill the other half of the carry-through to attach to a fixture for stress test, plan is to do only one side because if I have to re-inforce it I only have to fix one side before I build the other wing.

    IMG_20191112_151028.jpg IMG_20191114_200359.jpg IMG_20191116_120159.jpg
     
    Last edited: Nov 17, 2019
  4. Nov 24, 2019 #184

    proppastie

    proppastie

    proppastie

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    Figured I better post so I do not get any demerits.....Rivet of the spar....one of my simpler fixtures to put on edge.....do not want to rivet and have the sag in the tables show up in the spar...... added shims under the less than perfect table and the spar straighten right up. I laid the drag spar out in the Cad, but wanted to check it with a string (if you can see the string)....More than 1/2 the way done with the rivet of the LH wing spar today.

    IMG_20191119_204039.jpg IMG_20191120_150113.jpg IMG_20191124_124841.jpg
     
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  5. Nov 27, 2019 #185

    proppastie

    proppastie

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    Finished the spar, now working on best way to assemble so it is not twisted, etc. shown a thinking setup.

    IMG_20191126_154815.jpg IMG_20191126_200523.jpg
     
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  6. Dec 14, 2019 at 2:23 AM #186

    proppastie

    proppastie

    proppastie

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    been working on details for the spar in the flat as it is easier than after all the ribs/LE is added. Added mounting for tie downs, waiting for 1/4 nut-plates to finish. Two on each wing 1/3 and 2/3 out.
    Obtained 5/16 x 9 x 12 A36 plate for the load test. I have to match the holes in the fuselage attach angles without messing them up....Because the spar is now riveted I can pick it up and drill into the base of the drill press for square holes....much better. Real pain to match holes always always drill finished size at assembly, however that I am load testing pieces of the structure separately I have to violate that rule....My stress shows that 3/16 bolts will be enough for the limit test so the caps will be drilled out to 1/4 for the RH wing at assembly.

    IMG_20191210_200147.jpg IMG_20191213_120004.jpg
     

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