How I built my fuselage table/jig

Discussion in 'Workshop Tips and Secrets / Tools' started by Little Scrapper, Nov 15, 2016.

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  1. Jun 21, 2017 #41

    Little Scrapper

    Little Scrapper

    Little Scrapper

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    If I were to mass produce fuselages I would do it quite different. I would build a steel table and bolt it to the floor. I'd create a cage that opens up like a clam shell to build two sides. A simple hydraulic would close it and the other stations would get welded in. Those would be held in by lightweight removable fixtures. When done, the clamshell would open and you'd pull out the fuselage.

    However, it wouldn't be a Cassutt. It would be my version of the Vagabond.

    If I were king........ lol.
     
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  2. Jun 24, 2017 #42

    Little Scrapper

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    Finished the support stations this morning, I decided on 6 of them with 3 of the 6 focusing on the cockpit area. Anyhow, the table & jig is complete now.

    20170624_130046.jpg

    20170624_130127.jpg

    20170624_130220.jpg
     
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  3. Jun 24, 2017 #43

    Autodidact

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    That's almost a production fixture!

    Edit: Ha! BJC said the same thing.
     
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  4. Jun 25, 2017 #44

    Little Scrapper

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    It probably looks more complex than it is. Seriously, once you have tools, materials and an idea in your head it gets thrown together pretty quick.
     
  5. Jul 30, 2017 #45

    Little Scrapper

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    After cutting the table up and tearing off the supports I welded up to build the fuselage I built a rotisserie using the scrap parts. Below is how I did that.

    Knowing I'm just tossing the material out I didn't want to buy more steel. For a rotisserie I just need the fuselage to be held at numerous positions, I don't need anything elaborate.

    My thought was to first take 2 existing frame supports and screw 2 x 6's to them. Then weld 6 tabs on each top to keep the fuselage from sliding off. Real quick, no filler, no measuring, just weld and go.
    20170730_160721.jpg

    After 2 of those I need a kick stand of sorts.
    20170727_173745.jpg
    I used aluminum because that's what I had. Wood would certainly work.
    20170727_174124.jpg

    Cut and smooth out. This eventually gets bolted to the legs.
    20170727_175225.jpg
     
  6. Jul 30, 2017 #46

    Little Scrapper

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    For the kickstand legs I just walked up the fuselage supports that I used earlier.
    20170730_160813.jpg

    20170730_160833.jpg

    20170730_145843.jpg

    20170730_150325.jpg
     

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  7. Jul 30, 2017 #47

    Little Scrapper

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  8. Jul 30, 2017 #48

    Little Scrapper

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    3 pieces to the rotisserie, all made from the scrap of the table.
    20170730_165143.jpg

    Here are 3 photos that show how it can be held in different positions.
    20170730_165055.jpg

    20170730_165118.jpg

    20170730_165208.jpg

    Now the thread is complete..

    1.) Table
    2.) Table fuselage supports
    3.) Rotisserie from table scrap

    Time to weld.
     
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  9. Jul 31, 2017 #49

    Pops

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    I like everything that you have done. Good problem solving skills. I'm sure your Cassutt will be first class. Nothing better than flying and looking out at the wingtip and thinking, " And I built every part". A lot of pilots will never get that feeling of satisfaction.



    Pops
     
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  10. Jul 31, 2017 #50

    TFF

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    Nice welding stand.
     
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  11. Jul 31, 2017 #51

    Little Scrapper

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    Thanks guys. Now if I can just get my welding up to par. I'm incredibly out of practice.
     
  12. Aug 16, 2017 #52

    Little Scrapper

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    Ignore my advice on the stand. Seriously. All of us do it the same way and I'm comvinced it's bad advice, even mine.

    I experimented and raised me fuselage 5' in the air tonight. It was awesome.
     
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  13. Aug 16, 2017 #53

    Pops

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    How do you get anything done in such a clean shop? Makes me want to go to sleep. Nothing to step on or step over, nothing to bump your head on. Strange, Strange.
     
    Last edited: Aug 16, 2017
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  14. Aug 16, 2017 #54

    Little Scrapper

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    I'm building my airplane in my plumbing shop that customers see so I keep it clean every day. Because it's in a strip mall theres fire codes that prevent me from welding insides the unit. So I weld early in the morning and late at night when the fire inspector is sleeping, haha. I clean up and put everything away after I'm done because they do surprise visits.

    I'm also a bit OCD about having a clean shop for productivity reasons. Costs money to be disorganized in my line of work.
     
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  15. Aug 16, 2017 #55

    cheapracer

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    I made an extra table yesterday, grabbed an old steel framed bed, welded some extra height to the legs (800mm high total), threw some wood sheets on top.
     
  16. Aug 16, 2017 #56

    Pops

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    I understand , in running a business image is very important.
     

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