More welding practice. Starting to feel pretty good
welding this thin-walled tubing.
Had the time to tackle bending the rudder, for the 2nd time.
WELD PRACTICE !
Reviewed the plans for the stabilizers. Started laying out the pattern for the horzontial stabilizers. A question on one dimension. Laid out and
confirmed the metal ribs that I bought off of Dennis Fisher. Still need to make a few.
Finished making the jig for the stabilizers. All corner blocks are screwed in. I'm ready to bend tubing.
Bending one of the stabilizers.
One stabilizer leading edge completed. Five and a half hours. Hope
I'm a little quicker with the next one.
Bent the leading edge for the 2nd stabilizer. Must have learned something with
that first one. Shaved 4 hours off of this one.
Reusing nose blocks from incorrectly made Upper Wing tip rib.
Cut both out of bad rib, trimmed and sanded down. Cut additional gussets needed to make both tip ribs.
Modified the tip rib drawing to match the other Upper Wing ribs, cut the capstrips and glue up the first side of the first Upper Wing tip rib.
Looked over all the other ribs and replaced two gussets on two of the ribs. Just about done with the ribs. Finally.
Fitted up capstrips to 2nd Upper Wing tip rib, glued and weighted. Glued
and weighted up 2nd side of first Upper Wing tip rib.
Glued up second side of second Upper Wing tip rib.
Dremmeled off and re-glued a gusset that had moved on the first Upper Wing tip rib.
Trimmed/sanded nose blocks on Upper Wing tip ribs
Looking over plans... making list of 4130 sheet metal I need to purchase.
Still reading the drawings. Figuring out how much of each thickness 4130
metal I need for the fittings/brackets, etc.
Drawing up my first fitting on a CAD program.
Soon to be cut out of the flat stock I bought.
Worked on the last two tip ribs. Trimmed excess glue and overhanging gussets
off of ribs, cut plexi template to cut the trailing edge of the ribs. Cut and sanded trailing edges.
Went down to the workshop to start cutting some fittings.
Did a lot just to get to that point... cleaning up sawdust, looking for my caliper, etc etc. Spent 2.5 hrs getting ready
to do 25 minutes worth of cutting. Eeeesh !
Rough cut 2nd fitting to size. Took this fitting, and the one I cut the other day, to the grinder to trim to size.
More CAD work. More bend radius and set-back figuring.
Learned about figuring set-backs for something other than a 90 degree bend.
Drew up fitting SB3PW-0033.
Knocking out those CAD drawings ! Completed 6 drawings and re-figured the set-back on -054.
Getting the hang of this CAD stuff.
Cut two -057 fittings. Small... very small. Basically the blade broke and I hand cut the fittings. Slow to say the least.
Drawing more fittings.
Hand cut and finished 4 additional fittings.
Cut and shaped additional practice tubes for welding practice.
More CAD drawings. Knocked out three more.
More CAD drawing.
Cut a few fittings. Cut three blanks for -012. Rough cut one to shape. Still needs to
be ground to the finished size.
Spent almost 2 hours cutting two fittings to a close rough shape.
Spent another hour wondering why the bandsaw wasn't working. Fixed it in the end.
Finished rough cutting final -012 fitting, Ground all four to finished size.
Still need to file the insde opening on all four. Cut fitting -011 and ground down to size.
400 hours !
CAD drawing: Rudder Horn.
Cut and ground down (1) -010 and
(3) -057 fittings. Moving right along.
and filed two -036 fittings to shape.
Re-worked four CAD drawings to show
set-back and bend allowance.
Cut and filed one -036 fitting. Rough cut to
size the fourth and final -036 fitting.
Finished grinding -036 to size (.3). Ground one side of
a 1/2" x 3" x 8" piece of aluminum stock to a .25 bending block.
and ground to shape fitting -04, taking 1.1 hrs. Additional
.6 hrs I ground down the other side of the above aluminum
block into a 1/2 inch radius bending block.
Figured the bend allowance for fittings -050 and -051.
Cut both -050 and -051 fittings on bandsaw and ground down to size on the grinder.
Also finished grinding down the 1/2" radius bending block.
Drawing internal flying/landing wire
plates on CAD. Some info missing from the drawings. Asked on forum and got my answer within minutes.
Finished drawing the three above mentioned plates on the CAD program.
Material is 6061-T6 aluminum.