Dakota Hawk , Belfast Maine

Discussion in 'Member Project Logs' started by Danielle, Jun 26, 2012.

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  1. Nov 13, 2012 #61

    Danielle

    Danielle

    Danielle

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    after a slight delay in getting some new epoxy I was back at work on the Hawk. I started by cutting a 1/32 Aircraft ply strip to cover the seam on the upper floor that I had just installed . 100_1014.jpg Then I cut out the bottom floor from 1/8th inch ply and marked off all the locations that will get glue .This part off the floor will be boxed in so it need a two coats of waterproofing including the bottom of the upper floor that I just installed . 100_1015.jpg 100_1018.jpg After the poly was dry. I clamped down the lower floor using lots of epoxy . I also used a bunch of lead weights to make sure it was going to lay flat, The last project of the day was to install the bottom tail plate made from 1/8th inch ply. and of course a couple pieces of blocking . 100_1023.jpg 100_1024.jpg 100_1025.jpg DanielleN5660DH87
     
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  2. Nov 19, 2012 #62

    Danielle

    Danielle

    Danielle

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    The lower floor is now finished and most of the blocking that goes in on top of the floor. I also made the upper firewall frame which was laminated out of spruce .
    100_1026.jpg 100_1027.jpg 100_1029.jpg
    Danielle
    N5660
    DH87
     
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  3. Nov 22, 2012 #63

    Danielle

    Danielle

    Danielle

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    Today I epoxied the the upper fire wall frame in place. then cut and glued some control mounting blocking then cut two rear fuselage panels and clamped in place . I need to do some detail work on them before I glue them but it was fun to see them in place.
    100_1034.jpg 100_1035.jpg
    Danielle
    N5660
    DH87
     
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  4. Nov 24, 2012 #64

    Danielle

    Danielle

    Danielle

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    I wandered down to the shop early this morning hoping to get a couple hours of uninterrupted work done . I thought about epoxying the side panels but decided I did not have enough T-88 epoxy for that. So I rolled out the blue print for the rudder assembly . After some slicing and dicing at the band saw I had the basic assembly laid out.
    100_1047.jpg

    Then I decided to add a storage area behind Bulk head #1 . Something that could hold light bulky items like wing covers and winter jackets I made the base out of 1/8th inch play and made a small pony wall ( 4 inches ) that will keep small items from getting lose and going under the fabric or rolling to the rear of the airplane. Then used some geodetic strapping to frame the upper part of it . I keep the whole assembly under 1 pound of extra weight . When I do the weight and balance I will know how much I can hold back there .
    100_1044.jpg 100_1041.jpg

    Then I dropped everything and rushed across town to get more epoxy so I can glue the fuselage panels tomorrow.

    Danielle
    N5660
    DH87
     
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  5. Nov 27, 2012 #65

    Danielle

    Danielle

    Danielle

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    Still working on the rudder. Details, details, details, After it was all glued up I needed to cut blocking and gussets for every joint. when I walked away from the work table today you could hardly see the rudder under all the clamps that were on it.
    100_1059.jpg 100_1053.jpg

    And after a short delay I did get two fuselage panels epoxied in place I used one of those caulking tubes full of epoxy with a mixing tip and it worked great.
    100_1060.jpg

    Danielle
    N5660
    Dh87
     
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  6. Nov 28, 2012 #66

    Danielle

    Danielle

    Danielle

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    installed the last of the gussets on the rudder. Now it needs to sit and dry for a couple days then some major sanding and shaping .
    Also cut all the material for the horizontal stabillizer and elevator in hopes of starting assembly of that tomorrow. There was over thirty five feet of 3/4 x 3/4 and twenty five feet of 1/4 x 3/4 .
    Danielle
    DH87
    N5660
     
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  7. Dec 1, 2012 #67

    Danielle

    Danielle

    Danielle

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    The material for the horizontal stabilizer was all ready for me to work on. So after a couple hours of trimming and sanding parts I had everything ready for epoxy. Everyone who walk by my work area today commented on how big it was .

    100_1067.jpg

    Then after lunch I spent about an hour sanding and removing glue on the rudder. Then closed up shop for the day after hanging the rudder on the fin with a couple clamps just so I could see it in the morning when I walk in .
    100_1070.jpg
    Danielle
    N5660
    DH87
     
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  8. Dec 1, 2012 #68

    Danielle

    Danielle

    Danielle

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    While I was on a roll I decided to tackle the elevator and trim tab today . After only a couple minutes of cutting parts on my small bad saw it decided to break its blade which meant that the thirty some odd blocks like this
    100_1069.jpg
    would all have to be cut by hand or risk doing it on my big band saw which is kinda dangerous.
    i all so built in a trim tab on the left elevator which will get cut free once all the glue is dry then I will attach the hinges later.
    100_1071.jpg
    100_1072.jpg
    The temperature in my shop has been in the upper 40s and lower 50s so the epoxy will have to cure for two days before I can put all the gussets on it. so tomorrow I should be able to clean up the horizontal stabilizer.
    Danielle
    N5660
    DH87

    Edit
    I forgot to show the elevator hinge mortise that the stabilizer and elevator get. I used my router table with a very small up cut bit . You need to mask them off before gluing so they dont fill with epoxy .and of course make sure they all line up.
    100_1074.jpg 100_1077.jpg 100_1078.jpg
     
    Last edited: Dec 1, 2012
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  9. Dec 16, 2012 #69

    Danielle

    Danielle

    Danielle

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    Yesterday I built the door frames for my Hawk. I built them right in place,and used wax paper to keep them from sticking to the door jam. I did this so the fit was just right .Then this morning I removed them and cut the 1/8th inch ply outer panel and glued them to the frames .

    100_1158.jpg 100_1163.jpg


    After that I cover the trim tab with 1/16th ply .Eventualy I will cut the trim tab free of the elevator after all the hardware is attached .
    100_1161.jpg
    Last week I cut some nice Butternut in to what might become a instrument panel and laminated it to a piece of 1/16 ply. Here is a quick mock up of what it will look like .


    100_1147.jpg 100_1154.jpg
    After I decided it fit . I got out the Danish oil and gave it a generous coating It really made the grain pop .But this morning I noticed that it has started to cup a little. So I put some clamps on it with back pressure . I hope it settles back to normal after a while if not I will make it over this time I will us 1/8 inch ply. Right now there's not much more I can do untill all my parts arrive from FFP I have been told it should be here by Christmas .
    . 100_1156.jpg
    Danielle
    N5660
    DH87

    P.S. Roy I sent you a message about the C-90 did you get it ?
     
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  10. Dec 30, 2012 #70

    Danielle

    Danielle

    Danielle

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    Last week I tackled the fuselage streamers They are 1/4 x 3/4 spruce that attach on end and have there sides tapered to give the fuselage its shape. Each side has three and the bottom has three they are made from 1/4 x 1 1/4 spruce I only did the sides . After they were in place I threw a bed sheet over the body and fine tuned the tapper to get a nice smooth appearance .

    100_1197.jpg 100_1198.jpg 100_1169.jpg

    Today I spent my time working on the instrument panel cutting the instrument holes in the panel. the flight gauges are 3 1/8 inch And the engine gauges are 2.1/4 inch on the right . This is version 2.o the first one didn't turn out so well. this one looks a little better.


    100_1193.jpg 100_1191.jpg

    I also added a some padded leather to the turtle deck where it hangs over the instrument panel. I have not finished it yet. I may add some heavy stitching to give it a certain look . Right now its just tacked in place. working with leather is a new experience for me so I am taking my time on it .
    .
    Still waiting for a shipment of parts from FFP so I can move forward . The holiday kinda slowed things down some.

    Danielle
    N5660
    DH87
     
  11. Jan 17, 2013 #71

    Danielle

    Danielle

    Danielle

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    After a week of waiting for my parts order and not hearing any news I decided to start varnishing the exterior wood work with system three S-1 two part epoxy varnish and paint the interior cabin area with some sherwin williams porch and floor paint ( light brown ).I spent a day cleaning and sanding the interior wood so it wood look nice .I even turned the fuselage over and did the bottom .
    000_0011.jpg 000_0023.jpg 100_1201.jpg

    After painting the interior I added a small support piece to the lower door frame in case some one bears down all there weight on it getting in and out of the airplane. The fist time I climbed in I noticed it was easy to sit right on the frame.
    100_1199.jpg

    i also spent some time modifying the basic seat frame I added a three inch back to the lower frame and drill some large hole in it to remove weight then I added a front section to the base with a cut out for the stick to come all the way back to facilitate full stall landings .
    000_0013.jpg 000_0015.jpg

    Danielle
    N5660
    DH87
     
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  12. Jan 17, 2013 #72

    Danielle

    Danielle

    Danielle

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    Parts! have arrived, at least some parts have arrived . Wing tanks and all my AN nuts and bolts ,
    What I really need right now is the landing gear . I will keep my fingers crossed it will arrive soon. so I can move forward .
    Danielle
    N5660
    DH87
    100_1207.jpg 100_1205.jpg
     
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  13. Feb 8, 2013 #73

    Danielle

    Danielle

    Danielle

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    All my parts have now arrived it took me a few days to inventory and organize them .
    streamlined aluminum strut material for the wings.
    100_1246.jpg

    Matco wheels and brakes 6x8.00 cast aluminum wheels .
    100_1222.jpg 100_1223.jpg 100_1224.jpg

    Fiberglass front Cowling
    100_1253.jpg

    Now its time to get to work on installing the landing gear
    100_1247.jpg
    100_1270.jpg 100_1272.jpg

    Big snow storm headed this way tomorrow. I hope the electricity doesn't go out .I hope to spend some time in the shop working on the Hawk.
    Danielle
    DH87
    N5660
     
  14. Feb 17, 2013 #74

    Danielle

    Danielle

    Danielle

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    After getting the landing gear on. I was all excited to keep working on the Hawk but we had a little wind storm hear on the east coast I think it was called "Nemo" I lost part of the roof. So I spent most of this week dealing with that .
    100_1279.jpg
    Then I got to work on the control linkage first I laid all the parts out on the blue prints and did a partial assembly right on the table .
    100_1303.jpg

    After I was satisfied with the fit. I went to work hooking it all up in the cabin of the airplane .
    100_1330.jpg 100_1329.jpg

    Danielle
     
  15. Feb 20, 2013 #75

    Danielle

    Danielle

    Danielle

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    The elevator control linkage is now installed I made several nylon bearings for the tubing to slide through and am happy wiht the way it all works. I had to change the location of the exit hole for the elevator rod in the rear of the airplane to get a nice straight hook up to the elevator horn. It has25 degrees up and 20 degrees down travel .
    100_1346.jpg 100_1339.jpg 100_1347.jpg 100_1344.jpg

    Then I started working on the rudder cable sleeves these will get epoxied to the fuselage like the elevator bearings .The cable will run thru them to prevent rubbing on the wood .
    100_1352.jpg
    Danielle
    N5660
    DH87
     
  16. Feb 20, 2013 #76

    Danielle

    Danielle

    Danielle

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    I started the day working on my rudder cables. Then I installed the rudder pedal set up after wasting a lot of time trying to figure out which one was the left and which one was the right they seem to fit either side but they are different .Getting the brake cylinder at the proper angle consumed a lot of time also. I have heard a lot of complaints by Hawk owners about the brakes so I hope mine works .
    100_1355.jpg
    And then just when I was getting ready to brake for lunch my Upholster showed up with my seat Woo Hoo! I have been anxiously waiting for this moment and it turned out fantastic. a couple weeks ago I drove down to "Maine line leather" in Lewiston Maine and picked out a nice chocolate brown leather hide. Then I ask Lisa at LLISA Upholstery to do the work for me she spent several years working for columbia air doing upholstery for them . This is the first item on the airplane that I did not do the work myself, and at first I was not sure about it . But now I am so glad . I never could have made anything that nice . She made a place for the seat belts to go through in the middle of the seat, and she made a cut out for the stick to come all the way back so full stall landings can be made .
    100_1358.jpg 100_1361.jpg 100_1357.jpg
    100_1360.jpg

    Danielle
    N5660
    DH87
     
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  17. Mar 10, 2013 #77

    Danielle

    Danielle

    Danielle

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    I started wing installation yesterday . Just getting the wings up and in place with out damaging them took most of the day. Then lots of measurements and double checking the blue prints . When all seem right I bolted them in place . Tomorrow I will start bolting the struts in place.
    100_1379.jpg 100_1380.jpg 100_1381.jpg 100_1376.jpg

    Danielle
    N5660
    DH87
     
  18. Mar 12, 2013 #78

    Danielle

    Danielle

    Danielle

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    Wing strut installation was pretty straight forward . I started by installing the lower main strut bracket on the fuselage .
    100_1395.jpg
    At the base of this assembly there is a piece that you have to drill from opposite directions, it allows the wing strut to pivot around when you fold the wings.
    100_1377.jpg 100_1386.jpg

    After that assembly is in place you cut your strut material to length and install.
    100_1393.jpg 100_1384.jpg

    Making the jury struts was a new experience for me I tried to use a candle to soot the ends before heating the tubing, but a bic lighter worked better. The first one was kind crude and I may redo it but first I think I will let my tech councilor from my EAA group take a look and give me some pointers.
    The best thing about jury struts is now I have a place to hang my snowshoes when I fly to the cabin next year.
    Danielle
    N5660
    DH87
     
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  19. Mar 20, 2013 #79

    Danielle

    Danielle

    Danielle

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    I spent the week doing detail work on the ailerons and flap hardware . Now that its all in place I ended my day by epoxying the first pieces of the cabin roof supports . Time to get the cabin closed in .
    100_1412.jpg 100_1408.jpg
    Danielle
    N5660
    DH87
     
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  20. Apr 9, 2013 #80

    Danielle

    Danielle

    Danielle

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    Installing the windshield was fairly straight forward . But I took it slow . The last thing I wanted to do was to cut to much off and buy a new one . I used my roto zip and a sander to trim things up and get a good fit . I also used special acrylic drill bitts to drill all the hole to avoid cracking. i also m,made them oversized for expansion and contraction. Most of the trimming was done around the upper cabin top . Still waiting for a window gasket from Aircraft spruce . But here is what it looks like ( with the protective film still attached ) . Everyone keeps asking how can you see through that thing .
    I also attached my cowling. Now this was hard to handle . It was just to big for me to hold in place and mark the location by my self . So I spent two hours building a frame to hold it up and in the location I wanted .Then I marked and drilled . And I still got it 1/2 an inch to high . But I will leave it in place untill I actually get the engine mounted ,then I will adjust accordingly.
    100_1422.jpg 100_1423.jpg 100_1424.jpg 100_1421.jpg

    Danielle
    N5660
    DH87
     
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