Neirrh XXL build

Discussion in 'Member Project Logs' started by FritzW, Jun 19, 2014.

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  1. Jun 19, 2014 #1

    FritzW

    FritzW

    FritzW

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    The fuselage is a mixture of Legal Eagle XL and Stewart Headwind. I've got an 1835cc VW to put on it. I'd like to put a Maximizer re-drive on it but I still have some thinking to do on that. The wing is a "one off" design with Junker style flaperons and maybe VG's.

    The fuselage configuration, square in the front triangular in the rear, makes some sort of jig necessary. The jig I came up with looks like a Rube Goldberg mess but it was quick and simple to make on a CNC machine. So far it has done a great jog of holding everything where it needs to be while I get the tubing fitted.
     

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  2. Jun 19, 2014 #2

    FritzW

    FritzW

    FritzW

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    The first day was pretty much wasted effort. The longerons step down from 3/4 to 5/8. 43-13 and Bingelis are pretty vague on the best way to do this. On my first attempt I used an .028 "filler", fish-mouth and rosette welds to do it. I didn't like the way they came out so I cut them out and re-did them by re-sizing the end of the 3/4" tube down to 5/8" ID with a torch and a hose clamp. The splice came out much better.

    Longeron Splice 1s.jpg
    Longeron Splice 2s.jpg
     
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  3. Jun 19, 2014 #3

    FritzW

    FritzW

    FritzW

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    Once the longerons were spliced I clamped them in the jig and heated them at the bend lines and bent them into position. With the longerons in I can start filling in the rest of the tubes.

    Longeron bent 1s.jpg

    Neirrh Day 2s.jpg
     
  4. Jun 19, 2014 #4

    FritzW

    FritzW

    FritzW

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    P.S. This is what it will look like. ...one of these days

    Neirrh 7 s8.jpg

    Neirrh 5s.jpg

    Neirrh 2s.jpg
     
  5. Jun 20, 2014 #5

    FritzW

    FritzW

    FritzW

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    Day 3:

    I got the about half the bottom tubes in today. I'm hoping I can get the bottom finished tomorrow and start working on the top, then it'll start looking like an airplane.

    Neirrh Day 3s.jpg
     
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  6. Jun 21, 2014 #6

    FritzW

    FritzW

    FritzW

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    Day 4:

    I got the rest of the bottom tubes in. Measured and plumb bobbed everything to make sure it was all straight (the jig did a great job of keeping everything lined up) and tack welded it all together. There was a little creaking and popping when I was tacking but it all evened out. I'll start on the top half tomorrow. There are lots of tricky tubes to grind so things will probably slow down a little.

    Plumb Bob.jpg Making sure everything was straight and true

    Jig Alignment.jpg Alignment was good

    Neirrh Day 4s.jpg Neirrh Day 4
     
  7. Jun 23, 2014 #7

    FritzW

    FritzW

    FritzW

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    Days 5 and 6: almost have the front cabanes in, what a pain in the butt.

    The problem with a fancy jig is the tubes have to fit dead nuts perfect, there's zero room to fudge things. The way I did the front cabanes I have to fit both cabanes and a cross member at the same time (6 tube ends that have to match bends and clusters that are fixed in the jig) ...at the same time.

    I had to walk away from it today or I would have ended up at Happy Acres.

    ...I'm just whining, challenges like this are half the fun of building airplanes. But as soon as my blood pressure settles down to non lethal levels I'll be on the computer redesigning the rear cabanes;)
     
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  8. Jun 24, 2014 #8

    FritzW

    FritzW

    FritzW

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    Day 7:

    Once frame #2 was tacked in things started moving again. At least it's starting to look like a fuselage.

    Neirrh Day 7as.jpg

    Neirrh Day 7bs.jpg
     
  9. Jun 25, 2014 #9

    FritzW

    FritzW

    FritzW

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    I'm building this airplane on the "Design as you go" plan (not the best plan, but it is what it is;) One of the next steps is to figure out the landing gear. Before I commit to regular old landing gear I'm giving some serious thought to some sort of trailing link gear like the Wilga or one of the Australian STOLS Gallery of photographs from Australian Aircraft Kits

    Landing Gear.jpg Photo from link above.
    I'm shooting for an airplane with very good STOL performance so good "off road" gear is a must.

    -----
    Day 8:
    I got some more of the nose area put together and finished up work on the center longeron. I have to order some more tube to replace some screw ups made on Days 5 and 6. If I run out out of material before the new stuff arrives it'll give me time to start drawing up the landing gear;)

    Neirrh Day 8.jpg
     
  10. Jun 26, 2014 #10

    FritzW

    FritzW

    FritzW

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    I'll be waiting a few days for some more tube so I started working on some landing gear ideas.

    Neirrh Trailing Link Gear Mock Up.jpg
     
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  11. Jun 28, 2014 #11

    FritzW

    FritzW

    FritzW

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    I'm stuck until my tube shipment gets here on 7/1, but I did get some more work done on the landing gear drawings. It looks heavy but it's not as bad as I thought it would be, about 4 pounds heavier than regular gear (according to the computer). It's going to be draggy, no way around that.

    I'm thinking about using wings I came up with for another project (slats and serious flaps). It would save a whole bunch of drawing.

    Neirrh with Valk Wings.jpg

    Neirrh with Valk Wings3.jpg

    Neirrh with Valk Wings4.jpg
     
  12. Jul 3, 2014 #12

    FritzW

    FritzW

    FritzW

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    Day 9:

    The new tube showed up yesterday and I got the rear cabanes rough cut and bent (that was really day 9 but I'm not going to rename my photos;). Today I got the the rest of the cabin area finished.


    Jig Patch.jpg I had to add a temporary "patch" to the jig to hold the rear cabanes in the right place while I tacked them.

    Neirrh Day 9b.jpg I haven't tacked the front seat support in yet. It seems a little too high. ...I'll have to sleep on that before I tack it in.

    Neirrh Day 9c.jpg The project so far. The wing hanging on the ceiling is very similar to one I'll use. I just have to add leading edge slats.
     

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    Last edited: Jul 3, 2014
  13. Jul 8, 2014 #13

    FritzW

    FritzW

    FritzW

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    Day 10:

    I lost a few days with family visiting for Independence Day but I got a few more tubes in today. I was hoping to get the fuselage out of the jig this week but it's starting to look more like next week...

    Neirrh Day 10a.jpg

    Neirrh Day 10b.jpg
     
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  14. Jul 10, 2014 #14

    FritzW

    FritzW

    FritzW

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    Day 11:

    I started working forward from the tail post today and got a few tubes in. I've only got about 10 tubes left to go before it comes out of the jig. Then the real welding starts, at least it'll be a change of pace.

    It's killing me to follow the wooden airplane build threads;) For me working with steel gets to be a chore but I can work with wood all day.

    Grinder magnet.jpg Magnet under the grinder saves a little sweeping.

    Neirrh Day 11.jpg Working from the tail post forward
     
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  15. Jul 15, 2014 #15

    FritzW

    FritzW

    FritzW

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    Day 12:

    I finished all the 1/2" tube in the rear part of the fuselage today. I've only got about 6 tubes left ...a light at the end of the tunnel:)

    Neirrh Landing Loads.jpg Landing loads with trailing link gear (at least most of it)

    Neirrh Color Code.jpg This is a chart I use so I remember what size tube goes where.

    Neirrh Day 12.jpg The last of the 1/2: stuff installed
     
  16. Jul 17, 2014 #16

    FritzW

    FritzW

    FritzW

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    Day 13:

    Almost done. The fuselage is finished from the cockpit back. I still have a few tubes up front but they should be pretty easy compared to the triangle cross section stuff.

    If all goes well tomorrow I should wrap up the tedious grinding and fitting;)

    ...I'd better start thinking about a welding "rotisserie".

    Neirrh Day 13.jpg the light at the end of the tunnel is getting brighter!
     
  17. Jul 18, 2014 #17

    FritzW

    FritzW

    FritzW

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    Day 14:

    Oh happy day! The fuselage is out of the jig:ban:


    Neirrh Day 14.jpg
    I think the jig idea was a success, I'll do a few things different next time, like add more holes for clamps and make the firewall frame in two pieces (I had to cut it apart to get it out).

    Now I need a rotisserie so I can start welding...
     
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  18. Jul 21, 2014 #18

    FritzW

    FritzW

    FritzW

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    It was potluck day at church so I didn't get home in time to turn on the air conditioner in the garage. I just stayed inside and drew up how I want to do the rotisserie.

    Rote2.jpg

    [video=youtube_share;ThmZ5aIwxe8]http://youtu.be/ThmZ5aIwxe8[/video]

    ...I made a short video just for grins, I'll if this linking stuff works.
     
  19. Jul 22, 2014 #19

    FritzW

    FritzW

    FritzW

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    Day 15:

    I'm not one for over-thinking a jig:gig: This one took two 2x4's, a few pieces of scrap and a bunch of 'C' clamps ...and one hose clamp. The whole thing took about two hours to make. I did the wood and my friend (an O/A Welding Yoda) welded the steel parts. He wanted to practice before the real welding starts in the morning.

    Neirrh Day 15a.jpg Works like a charm

    Neirrh Day 15b.jpg Hose clamp keeps everything lined up

    Neirrh Day 15c.jpg The big 'C' clamp locks the fuselage in place

    Neirrh Day 15d.jpg It's a little "caveman" but it was quick and easy
     
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  20. Jul 22, 2014 #20

    FritzW

    FritzW

    FritzW

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    Day 16:


    Neirrh Day 16a.jpg
    I took the Jigosaurus apart today. It was kind of sad, like when you have to take the Christmas tree down, but it found a new home in Texas with a guy who wants to build an XXL (Mk-II Neirrh).


    Neirrh Day 16 Bill Madden.jpg
    My welding guru buddy, Bill, came over to help me with the welding. ...when I say "help me with the welding" I really mean "weld it for me". There ain't no way I could climb into those tubes and sit like that for 10 minutes. Maybe when we get to the easy clusters in the tail he'll actually let me weld on my own airplane[​IMG]

    Neirrh Day 16b.jpg
    'ol Bill does some nice welding.

    Neirrh Day 16 Fritz and Bill.jpg
    I'm the tall, dashing guy on the left, Bill's the ...err ...less tall, dashing guy on the right
     
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