Aluminum Dragon

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

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  1. May 14, 2019 #161

    proppastie

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    Finished cutting the Caps for the rear spar LH wing only....plan is to load test only the LH 1/2 the wing.

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  2. May 14, 2019 #162

    proppastie

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    Tip Load Grape.png Post-processor Screenshot.png I have been playing with a new FEA....here is same rear spar attach RH fitting in Grape and Simscale..... Applied 800# Tip load in the "Negative Airplane Y Direction" is shown... Grape is not in aircraft geometry but I have oriented the parts the same way here.

    Tip Load Grape.png Post-processor Screenshot.png
     
    Last edited: May 14, 2019
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  3. Jun 2, 2019 #163

    proppastie

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    still plugging away....shown plotting the rear spar on Mylar......drilling rear spar and checking hinge of aileron location ......interesting assembly issues when the hinge half is going to be riveted to the lower cap of the rear spar, along with ribs and drag spar not shown. Still thinking this through.

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  4. Jun 13, 2019 #164

    proppastie

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    Lots of holes.....hinges located,... caps drilled,...drilling for the stiffeners.

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  5. Jun 22, 2019 #165

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    de-burr of holes.....takes longer than drilling

    ready to bolt and rivet....decided to quick check if how I made the aft ends of the ribs was going to work.

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  6. Jul 14, 2019 #166

    proppastie

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    Bolted the overlaps....rear fitting, started riveting of LH Rear spar. Blue tape is where I do not want to rivet because ribs and gussets go there at assembly. In the past marking was not good enough to keep me from putting rivets where I did not want them just yet.

    IMG_20190713_205141.jpg
     
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  7. Jul 17, 2019 #167

    proppastie

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    finished LH rear spar.....blue tape is where the ribs are. all stiffeners are on inside because fabric will be attached to the aft side of the spar,...also shown cap overlaps, how I made a 22 ft long spar with 4 ft. long cap material cut from sheet.

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  8. Jul 22, 2019 #168

    proppastie

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    Tried to store the rear spar near the ceiling, but it was too flexible as it was, added a built up wood stiffener, realized would need 5 hands, ladders etc, so ended up taping to the side of the benches.....It remains to be seen if this is too flexible on the aircraft, the aileron will keep it straight at the hinge line, and the ribs/gussets/fabric might be enough, .....will see at assembly if I have to add an angle to the top cap. The stress analysis was good for the direction of loading (shear) .

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  9. Jul 23, 2019 #169

    proppastie

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    cutting caps for main wing spar,....there is .05 inch taper in 48 inch cut. the width of the first cap is 1.00 on the big end, and .90 on the little end. The fixture I made cuts picture perfect if it is set up correctly, which is a PTA. to do with my "classic table saw".

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  10. Aug 3, 2019 #170

    proppastie

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    plotted spar, checking fits to the drawing, I need to trim the drawing and paste to the spar web if I am going to use it as a template.
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  11. Aug 4, 2019 #171

    proppastie

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    Helps to look at the plans once in a while....ribs now going the correct way, and caps on the correct side of the web,....also trimmed and more accurately positioned the drawing/template.

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  12. Aug 5, 2019 #172

    proppastie

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    looks little more impressive now.....everything seem to fit ok.. ribs pretty much line up....making stiffeners and thinking about the assembly process. Probably will have to build the more tables I have cut, and clean out the basement some more.

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  13. Aug 17, 2019 #173

    proppastie

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    Drilling lots of holes, Drilling square holes on the table for the bolts.....can remove the front pulley to remove the cover....it is on a taper, slight tap with screwdriver under the edger of cover at the shaft. after the nut is off.

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  14. Sep 3, 2019 #174

    proppastie

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    De burr and reassemble minus web...piece of scrap to keep caps and stiffeners from racking/moving. Plan is to be able to get to the nose ribs in the leading edge to position for drilling. The assembly is very rigid with just the stiffeners and caps cleco-ed together.

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  15. Sep 16, 2019 #175

    proppastie

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    The battle of the Leading Edge.... Made two more tables........Tried to do it like the others I did on the tail .......2 mistakes and problems.....The wing top is more material than the bottom so I should have cut very oversize to allow each half to be the same when I taped up the trailing edges. Oh yes cutting the 31 ft aluminum was also interesting. Chapter 2 next post.

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    Last edited: Sep 16, 2019
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  16. Sep 16, 2019 #176

    proppastie

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    I used lots light plastic and rolled it and clips to secure the vacuum....that worked well as I could undo the clips and re-do I could not tape the trailing edge as the tape would not allow the two halves to suck down......also improved and clamped the pipe to each end of the part....just making the 22 ft pipe out of scrap water pipe was a story along with the clamps......still did not work as I had too much plastic that sucked to the bottom of the part and did not apply pressure where it was needed.

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  17. Sep 16, 2019 #177

    proppastie

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    I think it was the 4th try that it sucked down .....bunch of dents I will have to deal with but tapped a few out already and it will be covered in fabric,....Stits sells a filler that is compatible with their stuff.

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  18. Sep 17, 2019 #178

    proppastie

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    In order to move/handle I have to tape it together ...really did not turn out too bad, worst dents will be on the bottom, and looks like they will come out fine after fabric covering.

    I have to figure out where to put it....plan now is to hoist to the ceiling.....

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  19. Sep 30, 2019 #179

    proppastie

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    Sneaking up on it...can see LE up at the rafters as I check out my root template......Will have to remake the nose ribs longer, not stiff enough ahead of the end of the nose rib.

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  20. Oct 17, 2019 #180

    proppastie

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    Finished the nose rib re-work. Made more temporary web pieces transferred from web for strength and stability as I locate and drill the nose ribs. Made templates/contour boards for each rib, using ratchet clamps and parachute chord removed the spring clamps and pulled the LE into the contour boards with the ribs located. Drilling soon I hope.

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