My extraordinary plane build ...

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cheapracer

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Today I made a quick rough as guts jig from some scrap laying around to help with some leading edges

2 pieces of 50mm/2" pipe, some 25mm/1" square and some gussets.

On the right is a piece of 32mm/1.25" pipe.

There's about a gap of 38mm/1.5" between the 50mm/2" pipes.

Note the end close to camera has a bar across the top, I call it the end with the bar across the top.

jig 1.jpg

Note the other end does not have a bar across the top. I call it the end with no bar across the top so as to avoid confusion. I was considering to call this end Rupert, but finally decided on the former.

jig 2.jpg

Center your work over the pipes.

jig 3.jpg

Hook your 32mm/1.25" pipe (or smaller if you want sharper radius) under the bar.

jig 4.jpg


Lever the pipe down all the way through the gap, I put a 25mm/1" tube inside the end for leverage, and once down all the way through, I stick another in the other end as well to push that one all the way down. But you need to hold the first tube down - you may need another person to help depending on length of your workpiece. Note the lever has no name.

jig 5.jpg


I managed to lose the picture of the workpiece forced all the way down, so here's a Gay Spiderman dancing ...
gay spiderman.gif

So when you remove it, it will springback a bit. You can get a bit more bend by laying a few sheets of newspaper or cloth to tighten the gap some.

jig 6.jpg


It's still a little big here.

jig8.jpg


So to pinch it further, a couple of anything suitable, square tubes here, and clamp then together, removing and checking as you go. Make sure you tap the workpiece down with your hand s you go as it can pop up in one corner as you squeeze.

jig 7.jpg


You still here? What, you think there's more? What do you expect for nothing.

.
 
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cheapracer

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This morning I did the other side Elevator leading edge, so here's the picture to replace the one I lost yesterday with the workpiece fully pushed into the jig ..

This of course means no need for dancing Gay Spiderman (Sorry BJC).

jig 10.jpg


And the end result, 2 leading edges for the Elevators.

Jig 9.jpg
 

cheapracer

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.

It has been bought to my attention this morning that a couple of Members here have been sharing a story about Chinese cutting up humans, and canning them as 'Corned Beef" for shipment to African Countries.

I have deeply investigated this today and want to offer assurances to those concerned that absolutely no children or dogs are being added.

....


Quite proud of myself today, I arrived at the factory in the morning with not a clue how I was going to balance the Elevators, and by the end of not only figured it, but had 90% of it finished.

I grabbed a 25mm (1") square tube, cut some 19mm (3/4") flat steel and slid them inside the tube,

Balance 1.jpg

Balance 3.jpg


... sat it on the Elevator and juggled the tube and the weights around a bit, until it balanced. Got to seek out a reasonable ratio of length and weights.
The longer the lever, the less weight, the shorter the lever, the more weight required. At first I settled on this ..

Balance 2.jpg


But it was a bit long, so I got it a bit shorter by adding a couple more strips of steel on the outside (better fastener perch anyway), and now the Elevators sit where they are supposed to. They actually center themselves because the weight is a little below the hinge point.

Balance 5.jpg

I will tidy it all up and make some fiberglass covers at a later date, not important for the moment.
 
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cheapracer

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I had to have a few days rest, recovery after last years open heart still takes a bit out of me, but getting there, just slower than I would have liked.

But anyway, enough of that, I don't want you guys to get all upset and misty eyed over me and start donating money, well ok, a little if you insist, I promise to not spend it on expensive whiskey - 12 year old will be just fine.

Yesterday and today I played around with the VS and Rudder, measuring and figuring how to operate it. I ended up adding an extra rib next to the one at the edge of the tail, slotting the rudder, and slipping a lever arm through to be sandwiched between them, and riveted in place. Worked out quite nicely, though I will be changing the lever arm out for a different shape one.


Tail 1.jpg

Tail 2.jpg
 

cheapracer

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I decided I need a C Channel and another part easiest to be made in fiberglass, so moulded up a 50mm/2" steel tube and pulled a piece

C Channel 1.jpg


and handcrafted the other part which the mould will be ready tomorrow..

C Channel 3.jpg


Preparing some Swiss-Cheesed floor runners, all press drilled, I don't mind it, but it's boring after the first hundred holes, so can't wait for my CNC Router to arrive soon ....

C channel 2.jpg
 
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cheapracer

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I see an issue with the coronavirus that should be mentioned.

Some of you would note that the virus seems to be under control in China, well that's a truth that doesn't apply to most any other country in the world, and maybe offers a false hope.

Most Chinese live in high rise apartments, in secured housing compounds, around 500 to 2000 people. With the virus crackdown, every home can only have one member leave per day, unless you have a work pass. Your temperature is tested at the gate when you leave, and when you come back in. Same when you arrive at work.

So anyone who's temp is up, are spotted immediately, and either self quarantined and observed, or off to hospital.

This simply isn't going to happen in many countries with individual housing, many people will go days before they realise they are sick. This is what's happening in Italy right now and why it's spreading so fast.

So please don't relax on this just because it appears it eventually gets under control by China's example, it's a completely different culture.

I keep telling ya's, keep up the Vit C daily, 500 to 1000mgs daily, you can't overdose on it, and what's it going to hurt?

As VB says, wash your hands a bit more often, have more showers and wash out your nostrils too (your daily germs are breeding in your mucus). If you can't get hand sanitiser, use any alcohol.

No need for panic, no need for toilet rolls, just be a bit vigilant.

https://www.nytimes.com/2020/03/09/world/coronavirus-news.html
 

cheapracer

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The front floor board supports are in...

Floor 1.jpg

Pulled my (outer) mould off, it's fine, and using the same pattern for the inner mould by merely filling it up with resin and a bit of matting, with a chunk of foam to take up a lot of the volume.

I can use the same pattern for the inner because it's a simple rectangle with all sides tapered, and the inner will simply wedge into the outer. Will test the theory tomorrow :)


Mold 1.jpg
 

cheapracer

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After a few days rest again I did some more. Good that I'm slowly getting back to strength, but **** my knees are still a bit weak after a year of laying and sitting around, oh well, just got to keep pushing ...

I molded up my gusset/joining plate and pulled the part out this morning, now affectionately referred to as the 'ashtray' ...

ashtray 1.jpg

.. and this is what it does, joins the HS front spar to the upper and lower rear fuse sheets, and the mid-way post for the upper and lower VSs ...

ashtray 2.jpg
 
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cheapracer

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I finished the gusseting of the floor runners, had a thin piece of 3 ply laying around the shop, threw a layer of fiberglass onto each side of it to make it a bit stronger and waterproof it, trimmed it, painted it and one floor done.


floorboard 1.jpg

wood floor maybe.jpg

With all the mucking around though, I have the thought it might be just easier to go for a 100% wooden, zero aluminium floor, so I'm posed the question to the Forum Wood Experts here ..


.
 

cheapracer

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Guys, looking at Facebook tonight, there are people using China's current calm on the virus to suggest it's not a big deal, and that vaccines aren't necessary.

No way, please ignore it, the cultures and people's disciplines here are completely different, and is what made it possible, but not out of danger, please do not be apathetic about this.

In the last 2 days, Germany went from 10,000 to 20,000+ infections, in the same time worldwide it went from 200,000 to 280,000. Why aren't these numbers scaring people?

Northern Italy is just tragic, a reasonably small area and 800 more died yesterday, now 5000 deaths, and the first case was reported there only 7 weeks ago

 

cheapracer

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Well, I just looked at the virus numbers as I'm going to bed, it took 3 months to get to 200,000 cases and 10,000 deaths, it's taken just a further 6 days to double that, 400,000 and 20,000 deaths.

Anyone still think this isn't serious?

I'm worried about a lot of apathy I still see in America, please be smart, please be safe.
 

cheapracer

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YAY! My router arrived.

Busy today making a little house for him and having a play with it.

I would have thought the idiots would have done the calibration in the software supplied for and came with the actual machine, sigh ....

By the end of the day I even got it to run a small 2D file, no tool of course, long way to go yet ...
Still sorting through the various software out there too. until I find one I am comfortable with.

1212 arrived.jpg
 

cheapracer

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Well after spending most of the week sorting out and learning software and choosing between all the choices out there, yup, I'm using Sketchup. Just like the CAD program, the CAM plugin is just absolutely brilliantly simple.

After I downloaded the plugin, I had a test file running in Camotics toolpath simulator in an hour, and up and running the machine within the next hour, and can now make basic files in mere minutes

This was my first real test file ...

 

cheapracer

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And now back to making aircraft parts, this was a 'first run for real' tentative drilling operation today, worked out superb, 166 holes along each of 3 sides (500 holes) of a 20ft square tube.

What's critically important is the accuracy for matched hole building.



And here's the free program that made it so stupendously easy (2D milling that is)

 
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