Aluminum Dragon

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

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  1. Mar 12, 2018 #121

    proppastie

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    proppastie

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    still plugging away, all the ribs designed except tip which I realized has a skid attached, so need to re-think the concept for it. Ordered and received 23 ft. aluminum in a roll, decided I did not want to splice my spar webs.

    Got to start thinking about tables too, 22 ft of them, Guess if I was younger I could work on the floor, but that is no fun.

    ribs.jpg
     
  2. Mar 13, 2018 #122

    proppastie

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    Tip rib, with skid, and counter-weight. Probably will have to keep skid in clecos to assemble and line up the wing. Should have seen the first monster....this is the less complicated edit....

    skid.jpg
     
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  3. Mar 14, 2018 #123

    proppastie

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    wake up in the morning and lighten and simplify (?)

    skid2.jpg
     
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  4. Mar 19, 2018 #124

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    tip ribs and skids, have to wait till after wing is lined up and assembled to rivet the skit to the tip rib.

    IMG_20180316_111105.jpg IMG_20180319_133400.jpg
     
  5. Mar 26, 2018 #125

    proppastie

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    First of many tables for wing assembly. Modified EAA table. 2'x4' Has adjustable feet for matching the tables and level and flatness. I do not want to unroll my 23 ft. roll of aluminum to get more material to finish the ribs without the tables.

    IMG_20180325_153515.jpg
     
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  6. Apr 8, 2018 #126

    proppastie

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    Got 6 tables done, reviewing the wing assembly and it looks like 6 may be enough, but I have enough material for 2 more tables. Currently mounting lights, re-arraigning stuff to make room. Should have some pictures of the setup in a couple of days.
     
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  7. Apr 8, 2018 #127

    proppastie

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    matching and level tables.

    IMG_20180408_132825.jpg IMG_20180408_133005.jpg
     
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  8. Apr 13, 2018 #128

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    Ready to cut.....and Spar Webs front and rear, cut rolled and stored under table. I try to make paper templates from the CAD for everything, I find I make less mistakes than when I lay things out.

    IMG_20180410_145203.jpg IMG_20180412_220029.jpg
     
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  9. Apr 21, 2018 #129

    proppastie

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    I now have the large pieces cut or laid out and so am able to cut small pieces for the ribs. Not much different than previous work, just keep plugging away until it is done

    IMG_20180420_211007.jpg
     
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  10. Apr 22, 2018 #130

    proppastie

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    Third and Fourth rib from the tip RH and LH. Plot of assembly and flat patterns. Paste to aluminum (just bought 1 qt of rubber cement) and cut, line in middle is bend line. Holes are in the top pieces of the assembly for drill through at assembly after mounted in the jig. The plotter is within .01 and on 100% rag Vellum it is very stable. The pen plotter is better than my printer, but for small parts the printer would work ok. It is easier to keep the parts straight if I plot them all for any rib on one sheet. The only problem I have had is it is best to wait 12 hr for the glue to dry, as the vellum does not allow air through much.

    ribplot.jpg
     
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  11. Apr 28, 2018 #131

    proppastie

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    Switched to #4 finishing nails into soft pine for my rib fixtures.....It was easier to locate on the edge of the line, they drove in easier than the drywall screws. The soft pine works better than ply because it does not splinter and is softer.

    IMG_20180426_074821.jpg IMG_20180427_144601.jpg
     
  12. May 8, 2018 #132

    proppastie

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    I was able to talk a local mechanic into letting me use a very old bending brake he was not using. It probably is from the 30's it is massive but for perfection sake would need major re-work. My existing brake was rated for 22 ga (1/32) but the 4 ft. .025 hardened material was not bending straight and was very hard to bend. I had to use a pipe on the handles. Any slight variation in radius along the bend will cause a bow. The existing brake was flexing in the middle. All of these style brakes flex in the middle. Also often the middle is more worn. Even the big brake did not bend straight but the larger pieces were better and easier to bend. The smaller ones have a large bow. On these pieces it is not much of an issue because they will be straightened in the fixturing of the assembly and looking at the picture with the small clamps they straighten up easily.

    The big issue I was concerned about was the Trailing Edge, as there is a long distance between the Warren Style Ribs. However I was able to get it straight with the fluting pliers. It will be fabric covered so the flutes will not show. All in all it is going nicely, I have to cut out parts on the rest of that 23 ft. sheet so I can use the table to begin assembly of the aileron.

    IMG_20180508_073245.jpg IMG_20180508_095228.jpg IMG_20180508_095344.jpg IMG_20180508_095619.jpg IMG_20180508_095649.jpg
     
  13. May 22, 2018 #133

    proppastie

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    Got so tired of making ribs decided to cut up all the material for the rest of the ribs on the roll and the last 4 ribs (8 LH and RH) will be assembled as fill in upstairs in the small shop. I will hopefully start the assembly of the full span aileron next week because I will have the long table cleared off.

    IMG_20180521_111328.jpg
     
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  14. May 25, 2018 #134

    proppastie

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    The parts keep adding up,....starting setup for aileron....sort of like a big model, paste the wood over the plans, except it is aluminum.

    IMG_20180522_173229.jpg IMG_20180524_130337.jpg IMG_20180524_123937.jpg IMG_20180524_122323.jpg
     
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  15. May 29, 2018 #135

    proppastie

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    The 100% rag paper was not stable enough for 22 ft. of drawings....worked for the details but that was just too big, wrinkles bad dimensions. I ended up plotting on Mylar, and that looks much better. I am able to hold 1/64 over the whole 22 ft. and I am not sure if the tape measure is that good. Several minor changes to the design had to be made.....It looked good on paper so they say but when I saw the assembly I changed it. Riveted the splices on one long piece, and got my hinge material from Spruce.

    IMG_20180529_105656.jpg IMG_20180529_172604.jpg
     
  16. Jun 3, 2018 #136

    proppastie

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    Moving along.....sure would be easier with hard tooling assembly fixtures.... was really flimsy until I put the Trailing Edge on with clamps (not shown).

    IMG_20180531_111919.jpg IMG_20180602_165449.jpg
     
  17. Jun 6, 2018 #137

    proppastie

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    Farther along with a now almost hard tooling assembly fixture....notice the wedges on the spar mounting for that 8 degree tilt. Was into the 3d model to find where the trailing edge is flat.

    IMG_20180604_211453.jpg
     
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  18. Jun 10, 2018 #138

    proppastie

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    Almost broke down the setup to try something else.....Decided to work with it more and that I needed more clamps. Spent a morning making a bunch from junk laying around the shop. I now am satisfied I will be able to use this setup. Love the laser.

    IMG_20180609_125008.jpg IMG_20180609_125217.jpg
     
  19. Jun 14, 2018 #139

    proppastie

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    All drilled....not perfect, +- 1/8 on the trailing edge,...lets hope the slow speed it will not matter....that's what trim tabs are for. Next take it apart, deburr the holes and rivet. Might even have to add more ribs as between the hinges it may not be stiff enough. The trailing edge is "very structural" and carry the loads back to the spar through the "Warren Style" ribs. Note laser dot on hinge...the hinge line is within .05.

    IMG_20180613_135650.jpg IMG_20180610_210413.jpg
     
  20. Jun 19, 2018 #140

    proppastie

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    Pictures later... does not look much different finished from posted pictures,.....just finished riveting..... the assembly with ballast counter weight totals 7.72 lb
     

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