Fitting up spar brackets. Leveling... and re-do ears on spar brackets
May 18
1.3hrs
Filed down and fitted spar bracket ears.
May 19
2.7hrs
Sand ears, fit ears, put on spar brackets
May 20
2.1hrs
Sand of slag. Cut another cabane bracket.
1.1hrs
Fit up cabane struts.
May 22
1.6hrs
Fit up new ears. Put brackets back on spars. Made adjustments
May 24
1.5hrs
Adjustment to ears on UWCS spar brackets, mark, then sand down starboard ear.
May 25
1.6hrs
Tack then test ears/cabane strut for fit. YES!
May 26
1.9hrs
Fitted up front cabane struts... Level/adjust back spars, cut 2nd adjustable locator tool.
May 27
2.1hrs
Attached both adjustable levels. Made decision to cut off the two rear fuselage cabane brackets. Started the chore of cutting those off.
May 28
2.6hrs
Cut off rear cabane bracket from fuselage, cut out (2) new rear cabane brackets.
May 29
1.5hrs
Made aluminum test pieces. Cut irst doubler. Ground to size.
May 30
.7hrs
Cut out second doubler. Ground to size. Started grinding off excess weld.
May 31
1.1hrs
Cut off more weld from port side. Sanded brackets.
Jun 1
1.3hrs
Ground off starboard fuselage bracket and gegan grinding off weld.
Jun 2
.5hrs
More... grinding off weld.
Jun 3
2hrs
Weld new bracket halves the wrong way. Cut new 2-piece bracket pieces.
Jun 4
1.7hrs
Finish grinding and sanding new bracket. Welded both sides together of both new brackets.
Jun 6
1.1hrs
Drill all eight 5/16" holes in brackets.
Jun 7
1.5hrs
Files scratches out of brackets and file welds from last brackets that were left on fuselage.
Jun 9
1.2hrs
Align and tack on starboard bracket. Level UWCS to check cabane fit. Spar brackets don't match on the rear either.
Jun 11
1.5hrs
Take down UWCS from fuselage and rak rear brackets off (tube inserts made it difficult to remove rear spar brackets.)
Jun 12
1.9hrs
Cut off both bracket ears from upper spar brackets.
Jun 13
1hrs
Files and sand excess bracket metal left from cutting the ears off the brackets.
Jun 14
1.6hrs
repeat of yesterday
Jun 15
1.3hrs
Made second bracket wing start to finish.
Jun 17
1.4hrs
Filed inside of ears (where they connect to spar bracket) to fit to size. Sanding off paint from brackets so that I can weld them.
Jun 18
1.5hrs
Sanding off paint and surface scratches from the inside of the spar brackets.
Jun 19
1.5hrs
Re-attach spar brackets. Re-align and level.
Jun 20
1.4hrs
Align and fitting up of rear adjustable cabane (hole distance measuring) tool.
Jun 21
1.4hrs
Prep streamline cabane tubes for notching (attaching on papper cutting CADs)
Jun 22
1.1hr
Notched 2nd end on both cabane tubes.
Jun 24
1.3hrs
Started squeezing ends of both rear cabane tubes
2.2hrs
Finished squeezing ends of both tubes. Cutout and bent the four inserts for the tube ends.
Jun 26
1.4hrs
Cut, filed, trimmed all four inserts.
Jun 28
1.4hrs
Weld all four cabane inserts onto cabane struts.
Jun 29
1.3hrs
Drilled three of the four holes in the cabane struts.
Jun 30
2hrs
Drilled fourth hole, and then connected loose ears to both cabane struts and began leveling and aligning UWCS so that I could get a final mark on where the ears needed to be welded on the spar brackets.
Jul 1
2.1hrs
Aligned and tacked on spar bracket ears.
1.6hrs
Confirmed that the ears were tacked in the right location by re-attaching spar brackets, attaching cabanes, and then began welding the ears onto brackets.
Jul 2
1.5hrs
Finished welding (2) spar brackets.
Jul 3
1.4hrs
Welded up last (2) spar brackets.
Jul 4
.8hrs
Welding bracket.
Jul 7
1.7hrs
Sanded, filed spar brackets.
Jul 8
1.3hrs
Front (2) fuselage/cabane brackets welded.
1.3hrs
One rear fuselage/cabane brackets welded.
Jul 9
2hrs
Welded up (2) rear fuselage/cabane bracket. Started re-attaching spar brackets onto spars.
Jul 10
2hrs
Cut triangle corner blocks for additional support of Upper Wing Center Section box ribs.
Jul 11
1.5hrs
Nailed/glued on corner blocks.
Jul 12
2hrs
Spar brackets all re-attached to spars. Placed back into position over fuselage and attached all four cabane struts. YES!!!
Jul 13
1.7hrs
Figuring out the Dzus fasteners for the door on the turtledeck. Riveted on the spring to the plates.(that what happens when you step away from a project for a long time)
Jul 14
1.7hrs
Got it figured out. One of the springs is off centered on the plate. YOU won't see it, but I know it's not to my EXCELLENCE. Decided to re-make the plates for the springs. Drew up the new patterns on DeltaCAD.
Jul 16
1.8hrs
Cutout and drill, 1st bend on (2) new Dzus plates
Jul 17
1.9hrs
Work on Dzus plates, bend cut fit
Jul 18
.7hrs
Cut wood doublers for Dzus plates and glued onto plates (so that I can glue to turtledeck... also the thickness takes up the space where they need to be glued).
Jul 19
1.5hrs
Sand down wood doublers for perfect fit in slot on turtledeck. Glue into place.
Jul 20
1.5hrs
Started welding on tear drop reinforcing plates on cabanes
.5hrs
finished first welding on tear drop to first cabane... Fitted up tear drop to 2nd cabane
Jul 21
2.3hrs
Weled on tear drops to 2nd and 3rd cabanes
Jul 22
2.7hrs
Weld on tear drop to remaining cabane. Re-attached brackets onto spars.
1.1hrs
Squaring up upper wing center section. Started figuring out the length of the sway wires.
Jul 24
1.7hrs
Measuring, marking, cutting hole openings in upper worwrad skins.
Jul 25
1.1hrs
Making pattern for initial holes for top skin.
Jul 26
2.8hrs
Cut rough hole locations. Re-attached skin to fuselage... started tweaking locations.
Jul 27
1.6hrs
More tweaking of holes. Screwed upper skin back onto fuselage.
Jul 28
1.8hrs
Upper Wing Center Section nicely squared up... with new 1/8inch cord I bought. Using the twine to do it... sucked!
JJul 29
.7hrs
Measured and CAD'd up hole openings for forward skins for consistent size.