Aluminum Dragon

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proppastie

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Main Spar is designed, working on nose ribs and LE calculation, Have to 3d model each spar nose rib station and LE to get the Area and I (moment of inertia) to trick my linear FEA.

Decided to make some metal. Checked the feel of the rudder bar on my foot where my foot will sit, seemed OK. Did some bending and welding almost done, just have to add the cable hook-ups and cap the tubes, then mount on Tube. Shown about where it will be except little forward. Have to take off the skid to get it in where it is going to go. Changed the design of the stirrup because the cables will hookup to the bottom of the stirrup and it therefore needed to be stronger.

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proppastie

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Where I exactly sit, has been the subject of investigation with 3d models of the wing, spread sheet W&B calculations of various weight pilots etc. I wanted to make the seat pan as small as possible to save weight. So anyway decided I had a fair idea that the location of the seat will be ok and tired of making drawings and calculations decided to go ahead with cutting some metal. Felt good to get back into the shop. Plotted details and assembly of the seat supports. Cutting straight lines with the Olfa knife and hardened straight edge. Decided to try drilling without the complications of the "fixtures" just held the parts over the drawing and drilled, seem to work pretty good, or just as good as with the fixtures.

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proppastie

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Was at a very satisfying music festival in Nashville (Americanafest) for the last week. But had decided before I left that I needed to borrow (get back) the small drill press I had given to my son. He drove from Illinois and I flew from NJ for the festival. I flew back today with the drill press for my spar fabrication.
I finished the detail design of the seat back while there. Pretty soon I will be able to sit and make airplane noises.
 

proppastie

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New old drill press, the idea is more portable square drilled holes for the spar on the 22 ft spar assembly table. Will have to fiddle with spacers to get the spar level with the drill press. I can remove the guard and moveable table and slide the head down.

All the holes drilled in the seat, ready to be removed, dimpled, riveted. Ordered 3/32 diameter Stainless blind rivets. I can recommend these people....https://www.baysupply.com/

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proppastie

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Seat is done...weighs 1 #, TLAR and happy with it, I can stand on it no problem.

need to work on rudder bar heal support.

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proppastie

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I decided to check my welding manual, and found that a 00 tip is recommended for 1/32 thick material. Checking I found an equal size with my Mini-Torch. Some of the easiest welds I ever made....the filler flowed like solder and not one blow through. If all else fails read the instructions.

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proppastie

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adding doubler and stiffener angles for seat back hinge. Had I been smart enough to know I needed these stiffeners, they would have been straight, as it is I have to work around installed rivets.

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proppastie

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Almost finished seat supports. Inserted bushings in the seat back for the supports, I need to weld the bushings, drill 2 more holes bottom/attach location of the supports, trim and clean up the supports, prime the steel, and then cover the seat back with PolyFiber and 2.7 oz Dacron fabric.

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proppastie

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The Primer pealed off when I tried to coat with Poly Brush. It only took an hour to remove with my fingers. Probably too old (get what you pay for). Will be exploring Powder Coating.

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proppastie

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I re-primed the Seat Back and will wait a week for it to dry ....see if I can make what I have work. Mooney annual time and that usually takes a week, so I guess it works out. Worked on some stress analysis for the LE of the wing. Primed two supports for the seat back .... they are not fabric covered so I can use Rust-Oleum.

Edit: just noticed I forgot to trim them.

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proppastie

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Glue the fabric, smaller clamps worked better on the second top piece, big ones would not lay flat with the other piece of fabric in the way. Pull against to clamps to glue the first side. Shrunk and tried out, it is comfortable .....love it when a plan comes together. Still have to add the tapes, and finish it but wanted to see how it felt, and think about improvements to the rudder bar, and location of stick.

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proppastie

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learning Poly Fiber by the book, glad it is not something too critical or big. I should have done a work shop at Oshkosh or Sun and Fun it is not easy to know what is too much Poly Brush or not enough, along with other "learning experiences" Those cheap chip brushes stink, keep shedding fibers. Had a decent plastic fiber brush and the Mek did not dissolve it so it must have been polyester, That worked much better. I should have made my tapes bigger.

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proppastie

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Finished the 100 hr./annual inspection on the Mooney....getting too old for that. Bought a Pinking Shear. Started to patch the open holes in the seat back. Turns out according to my fabric guy I need to close off all the open holes to keep bugs and dirt out of between the fabric. Not sure how that applies to drain holes but that is a worry for pretty far down the line.

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