Yesterday I built a 8 ft sheet metal brake that I going to need to bend the spar webs channels for the center section , and outer wings. I found this inexpensive brake on the EAA web sight that a person build. I’m pleased with how it worked. Here are 3 test samples in the picture of metal that I bent , from right to left, right picture, no set back, center 1/8” set back, left 1/4” set back. In the article person describes one 1/8” setback as working the best and it looks like it does. It cost about $350 in Materials to build a brake, not to bad considering what they want for a production Built brake. The worst part of the whole build was drilling the holes in the stainless steel hinge. Had to rent a magnetic drill to do this. Tryed to do it with a hand drill but couldn’t get enough pressure and turn it slow enough to cut through the stainless. Took about a hour to drill 100 holes through the hinge.
The The Today I built a 23 ft table that I have the center section & outer wing panels layed out on. I just had to get it up off the floor. It about killed me off , but it’s done! I think I’m going to take tomorrow off & recover from this two day building spree I’ve been on ! Having a good stiff drink here this evening ! Sorry for the double pictures.
I have been making cap strip’s for the outer wing panels the last 2 weeks. Must have drilled 1000 holes it feel like, and de- burded on both sides! Ran out of material to finish making the cap strips. Everything to continue on with them hasn’t arrived. Everything about 3to 4 weeks out . Material for the center sections cap strips should arrive here Friday. Guess if that shows up I’ll work on that. Here’s a few pictures.
Friday the aluminum sheets arrived , wasn’t expecting it till Monday. Luckily my friend a couple of hangers down has a forklift, came in handy lifting the 950 LBS pallet out of the shippers truck! A friend of mine just happened to show up when all this was taking place, and helped me unpack the pallet & move all the sheets of aluminum into the hanger, about 16 of them. Sure was glad he was there! Alodined 1 completed set of cap stripes before all this took place. Turned out nice I think. Spruce has shipped the rest of the cap strip material I need to finish off the Strips should be here on 4th if March. On Monday I’m taking the drawing over the shop so they can get the measurements needed to put it on a program so that they can run it on their CNC router to cut out the center section caps strips once they’re ready I’ll take the material over and it shouldn’t take them long to get that done. Still waiting on some other parts that are probably three weeks out ? Hopefully they will arrive early? Here a couple of pictures of the alodined cap stripes that are finished.
Yesterday I received the rest of the cap strip material ,and bandsaw cut the to ruff shape , then started belt sanding them to final shape yesterday. Today I finished up the belt sanding , then polishing them, got them done and started laying out the rivet hole spacing until I burned out! Tomorrow going to be a long day on the drill press! On Monday I dropped the drawing off at the machine shop so the could take them and make a program to use on there CNC router table, they called me the next day and said to bring over the material the following morning, so a friend of mine came by and helped me load a 4’x12’ x1/8” sheet of 2024 T3 and we took it over. They said the center section cap strip will be ready early this coming week. I couldn’t imagine trying to cut them out with a jigsaw and shape them ,it would take forever! I asked if I could come over and watch them cut them , but of course they said because of insurance purposes I couldn’t, I sure would like to see them do it ,it be pretty cool I bet! Here’s a couple of pictures of the cab strips. I should get these knocked out by Monday. I have a Lotta holes to drill a lot of d-buring to do, and then alodine them.
Today I final finished all the cap strips! Got to thinking about how many hole I drilled & D-burred? So I did the math, couldn’t believe it ! Total holes 6,432 , total holes D-burred 12,864 ! No wonder it took me so long. They turned out real nice, a thing of Beauty Ha ha! Don’t want to do that again for awhile! Should be getting the center section cap strips in a couple of days.
Yesterday morning I picked up the center section cap strip from the machine shop that cut them out of a 4’x12’x1/8” sheet of 2024 T3 for me on a CNC router table. I can’t get over how nice they look and came out They are a perfect fit from the drawing I took to them. I couldn’t imagine trying to cut them out with a jigsaw and then file them to shape! There is no way in the world I could get them to look or be a matched set like this! Couldn’t be happier! Here the pictures of them. Just need to hit the edges very lightly with a file , polish them!
Yesterday day I remove the bulkhead from the fuselage jig that the center section cap strips will be attached to , and attach it to the layout table to see how it looks. Then stood there for a couple of hours measuring . Here are a few pictures. Still need to finish polishing the edges of the rest of these cap strips, lay out the rivet holes before thing get serious about attaching the cap strip.
Friday we had some weather come through here , starting in the early afternoon, so I didn’t get all the pilot holes drilled in the center section cap strips. Power went out at the house at 9 pm, and was off for 24 hours,50+ mile an hour wind, and a low of 8’ without the wind chill, Burr! Back at it today, I finished up the pilot hole , laid out & alined cap strips to center section Bulkhead. Got a lot done, and things are looking good. Need to drill all holes again to final size, and finish polishing all the edges. Here are some pictures .
Finally finished up the center section cap strips, took longer than I thought it would. There are so many hole to drill, each hole was drilled 3 times. Finished Aloding the last of them today. Made 1 center section spar also today. Here the pictures.
Continue on today with center section, made the remaining inboard Spar , alined everything and drilled center section cap strips to the center section spars. Need to get some more sheet metal fasteners that are long enough , 1” to pull all the Strips up tight before riveting , this is going to be a messy job when the time comes, rear side’s of cap strips closest to the bulkhead are going to be sealed for a fuel tank. I can hardly wait to get the pro-seal mess going. It’s been several year since I sealed the tanks on the RV over there when I built it & haven’t forgot the joys of working with the nasty stuff! Hopefully they are open & can send them out Monday?Been a long week, thinking of taking the weekend off , and starting fresh on Monday.
Finally about to get it all together in one piece. Still not finished , it all gets taken apart , all metal cleaned & painted before final assembly. Going to be a little While until that happens. Waiting on the rivet squeeze to arrive to squeeze the 5/32 rivets in the center section cap strips. It 3 to 4 weeks out! Guess I’ll start on the fin & horizontal stabilizer while I wait.
Finally back at it a little , after not touching it al summer.
Winter is in the air in northern Idaho , so it time to get after it again.
Last couple of days Cut the outer wing spar to length , and drilled in spar cap stripes , and the outer Attachment brackets. Still a lot of prep work to do before everything goes together for good.
Started building leading edge fuel tank . Pictures are of rid attached to rear bulkhead of the. Leading edge fuel tank .
They will be separated , and removable of the main spar like a RV leading edge fuel tank. Just more complicated to build because the leading edge is tapered ,all the ribs are a different size . The RV is straight Leading edge, all the ribs are the same size .
Made the opening’s in the fuel tank bulkhead today in one of the leading edge fuel tank‘s , a lot of drilling, filing, laying out hole’s , making patterns ,deburing , polishing, dimpling . Waiting on material to finish making the covers. Making progress. Need to get after the other side now.
Well I got the holes in the other bulkhead for the other leading edge cut out and ready for all the nut-plates to be Install. waiting on a fresh batch of Pro-seal to arrive, and the aluminum to make the cover plates. Going to get messy pretty soon.
Nut plates are all pro-sealed on and ,yesterday I build the jig to hold the leading edge fuel tanks that was fun getting everything plum & square with the world. Today bent & ruff skin to shape, trial fit it ,removed skin and the started locating all the hole on the ribs & rear bulkhead for the fuel tank , didn’t quite finish that before I burned out. Tomorrow is another day ! Here some pictures.
Made a little more progress today , finished drilling hole’s in tank rear bulkhead , then getting the tank skin pulled down snug against the rib , after that rechecked the alinement to make sure it has the proper washout , and started back drilling the holes to the skin. It sure take a lot of time to do this , and you have to be a contortionist to get under there to back drill the holes . It’s Friday, I’m quitting early today .