LEXLD94SE

Discussion in 'Member Project Logs' started by steveair2, Apr 28, 2016.

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  1. Dec 17, 2017 #21

    steveair2

    steveair2

    steveair2

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    Today Jim made some good progress on the seat, then we finished welding the top of the cabin section.
    We glued some poster board together and started mocking up the windshield section.
     

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  2. Feb 5, 2018 #22

    steveair2

    steveair2

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    Today we installed the seat support structure. Jim found a nice little foot switch for our grinder. This grinder set up with the sanding disc is one of the best tools for coping tubing.
     

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  3. Mar 12, 2018 #23

    steveair2

    steveair2

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    Yesterday after our EAA Chapter 280 meeting we did some welding and tacked in the wing attach fittings.
    We also checked out some foam for seat cushions.
     

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  4. Mar 19, 2018 #24

    steveair2

    steveair2

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    Yesterday we cleaned and welded on the frame. Jim sprayed a little rattle can Rustoleum.
     

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  5. Mar 25, 2018 #25

    steveair2

    steveair2

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    Today we continued cleaning and welding.
     

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  6. Apr 22, 2018 #26

    steveair2

    steveair2

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    Today we started building our landing gear, lift strut attach fitting jig. We're making poster board patterns for our fittings.
     

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    Last edited: Apr 22, 2018
    nzdavmo, Joe Fisher, Propman and 3 others like this.
  7. May 21, 2018 #27

    steveair2

    steveair2

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    Today we worked on our poster board patterns and cut the first two fittings. We added a lengthened tab on the front fitting that after bending eliminated a fitting to frame gap.
    We've tested side by side the Milwaukee and Diablo 12" metal cutting blades in our recipricating saw. They both perform great and are equal in performance. The 12" blades make cutting very straight lines easy. We used a small triangular file to cut a notch in the metal before cutting easing the start of the cut. We still have a little adjusting to do on these before moving to the next set. It's worth the extra effort!

    We have also tried several types of commercial rust preventatives over the years. We now use cheap vegetable oil applied with a rag. The oil can be thinned and or cleaned off the tubing with acetone. It works great.
     

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    Last edited: May 21, 2018
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  8. Jun 5, 2018 #28

    steveair2

    steveair2

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    Today we cut drilled filed and fit, the remaining six landing gear fittings.
     

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  9. Jun 12, 2018 #29

    steveair2

    steveair2

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    Today we continued bending, shaping and fitting the landing gear fittings.
     

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    nzdavmo, Joe Fisher and mcrae0104 like this.
  10. Jun 18, 2018 #30

    steveair2

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    We had some nice cloud cover today keeping the shop cooler and we made some great progress. First we finished bending and fitting the fittings, then we filed all the edges smooth. Starting with a coarse file then using a medium file then finishing with a fine file. Then we polished them with emery cloth. We still have much work left to do on these fittings.

    This reply continues to reply 31
     

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    Last edited: Jun 18, 2018
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  11. Jun 18, 2018 #31

    steveair2

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  12. Jun 25, 2018 #32

    steveair2

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    Today we removed our wooden landing gear fitting jig, and built a new one from one inch square steel tubing.
    We started building a drill guide to locate the bolt holes in the fittings.
    I decided to measure once and cut twice several times, and Jim tack welded the drill guide with the TIG welder.
     

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  13. Jul 2, 2018 #33

    steveair2

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    It was a delightful 104 degrees in Joshua Texas today. We continued working on our bolt hole locating fixture.
    I'm too exhausted to explain much about our drill guide. The pictures should show our process.
    In the next to last picture it is clear that something went wrong. We think our steel rod deformed at bit.
    Jim has some nice lawn art, a Dormoy Bathtub and an original design autogyro.
     

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    Last edited: Jul 2, 2018
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  14. Jul 9, 2018 #34

    steveair2

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    This morning, Jim cut out the crooked bushings and then put radius's on all our landing gear fittings. We then re jigged everything, and used 1/4" music wire to line up our new bushing in our drill guide.
     

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  15. Oct 22, 2018 #35

    steveair2

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    Today we were able to complete the welding of the cabin section, and then we cut fit and tacked in the seat back gussets.
     

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  16. Oct 29, 2018 #36

    steveair2

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    Today we completed more welding and Jim modified our drill guide.
     

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    nzdavmo, FritzW, cdlwingnut and 4 others like this.
  17. Nov 17, 2018 #37

    steveair2

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    We had great weather today and made some good progress. We changed the last single diagonal at the tail post to two diagonals. We're using a Harbor Freight propane torch to pre heat our clusters prior to welding, and are currently welding the tail section.
     

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  18. Nov 25, 2018 #38

    steveair2

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    Today we had more good weather with temperatures in the mid seventy's. We continued welding though the tail section. Using the propane torch to preheat the clusters works really well. The propane torch is also used after welding to cool the joint down slowly.
     

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    Last edited: Nov 25, 2018
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  19. Dec 1, 2018 #39

    steveair2

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    Today we were lucky to have another warm day in the mid seventy's. Thinking that this might be the last warm day before winter, we decided to get as much welding done as possible. We welded for fourteen hours straight stopping once to eat pizza while standing. We finish welded the tail section and then tacked in the two diagonals at the fire wall.
     

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  20. Dec 18, 2018 #40

    steveair2

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    After our last welding session, Jim primed and painted the tail section. He also rough cut the engine mount gussets. Today we finished shaping the gussets and installed them into the firewall. Then we laid out and drilled the 1 1/8" holes and installed the engine mount bushings.
     

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    nzdavmo, FritzW, cdlwingnut and 3 others like this.

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