Figuring out punch list. Made phenolic washer for trim handle.
Tail spring bracket - cut off and re-designed, re-CAD'd.
Made new tail spring bracket, part A.
Made new tail spring bracket, part B; the sleeve that holds the springs.
Modified part B; made second sleeve that the first one fits into to build up the thickness. Build up thickness of sides so that the bolt head is far enough away from the lower longeron.
More work on part "A".
Attempt to align tail spring. Not working...
Didn't have fuselage level. Leveled then algined and tacked on tail spring bracket.
Not happy with tail spring alignment. Another attempt to align. Tacked... still not happy with it.
More work on the tail spring bracket.
Build out revised cup sides.
Made new bushings on lathe. Welded on skewed !
Cut bushings off. Grind/sand off old weld. Re-weld on straight.
Weld on Part B (plate) to fuselage. (weld is too close to holes STILL)
Start thinking and working on tabs for seat belt connections. Started designing but then needed to investigate what size holes needed to be made for the connection.
Made new Part B (longer) and cut/filed off old Part B from fuselage. Welded on new Part B.
Figuring out set belt hard points.
Made rotisserie for nose of fuselage - for spining.
Still figuring out hard point locations. Make patterns. Rough-cut pieces out of .o71 4130.
Grind/file/sand to shape. Burn patterns off. Sand front and back faces smooth.
Check and re-size hard points. Weld 6 of 8 onto fuselage.
Welded on 7th and 8th hard points for seat belt harnesses. Made control stick shafts for front and rear pits. Made fitting so that NAF 1173-2 stick grip with 1 1/8inch hole would fit onto 1inch shaft.
Work on the pilot's control stick. Trimming, fitting, welding on of the top bushing, and cutting the V's into the lower section for welding and then welding on the stick.
Work on the second control stick.
Welded V on front stick. Drilled out existing 3/8inch bushing in rear stik - reamed - cut and welded in new bushing.
Rear stick boot needed some attention - worked out the problem with it being too narrow.
Needed to re-work bottom of each of the stick sockets (needed to squeeze them in) to 5/8inch) etc.
Prep for connecting push rods. Figuring out what needs to be done to get it done. Took measurements. Need to purchase some 10-32 x 1inch bolts.
Spent about an hour on it but didn't get anywhere with anything... Did research on what size drill hole for a 10-32 bolt. Getting conflicting answers.
Started drilling the push rods with bearings. Screwed up the first stick and a $55.00 bearing ! Bearing twisted while drilling. Made jig to hold bearing in place. Will try again.
Glue false rivets in instrument panels. Figuring out location of cut-outs for the webbing on the seat belt that goes through the turtledeck opening. Drill attempt on first bearing for push rods. Tube twisted and I ruined the first bearing. Need to re-think and make a good jig for holding tube/bearing.
More measuring and marking of holes for openings in turtledeck door for seat belt webbing. Not real confident that the openings in the guides I made are going to work. May need to re-make.
Needing to figure out size of opening for seat belt webbing (with ends). Send email off to Hooker Harness.
Received order for drill bits, 10-32 bolts, washers and nuts. Used jig I created for a few tests. Drilled all four holes for first push rod tube.
Drilled all four holes for second push rod tube. Went to attach and found that I left the tube in the walking beam too long. Will need to cut down.
Filed down the too long of a tube in the first walking beam. Looks and works good... just a little cleaning up.
Filed second walking beam's tube so that bearings had clearance. Measured, cut, and drilled four holes in third push rod. Set-up fuselage for last connection. Need to buy additional tube to finish.
Re-design seatbelt webbing guides ?
Do I need to re-design the webbing guides ? I need to find out the actual hardware that is used on it.
Researching Hooker Harness on the iternet - sending an email to them asking the question about the size of the hardware.
Attempting to figure out why the hell the stick grip is basically going through the passenger seat when showing a 25degree push forward. Two hours... and I figure I can't use the grip. Needs to be something more compact and directly around the stick. Took the grip off and... that's the issue.
Triple checking the length of the last push rod after triple checking that the grip was indeed the culprit in last night's woes. After confirming length I marked and drilled push rod for both bearings. Tested on fuselage and it WORKS !
Re-work the back stick-boot and stick so that I can use the WWII stick grip I bought. As it is... the stick is kinda close to the back of the front seat when full 25degrees forward.
Finished re-work on pilot's stick boot/stick/stick grip. Tested... looks great !
Re-work front stick booth.
What's up with the front stick boot?
Cut the blanks for the new seat-belt web guides. 2.75inches wide at the opening.
File and sand all four, new webbing guides. Grind off, file and sand areas of four existing guides on fuselage.
Cleaned up guides before welding onto fuselage. Welded all four onto fuselage.
Re-worked front stick-boot in cradle off of fuselage. Welded on angled piece to stick-boot. Drilled 3/16inch hole for removal front stick.
Decision on how to attach the rear instrument panel; four brackets attached to the lower portion on the pane and one, centered at the top ?
Match-drilled rivet holes in all four brackets. Aligned and tacked onto fuselage for finish welding.
Align and weld on four instrument panel mounting brackets. Figure out how to attach/stabilize top of instrument panel. Designed bracket - drew up on CAD.
Figuring out attach brackets for front instruement panel. Realized that the front panel will need to be modified because of the sway wires. Cut out paper pattern to figure this all out.
Cut out top support bracket for the pilot's instrument panel, along with the two tabs that will get mounted to the fuselage for attaching said bracket to fuselage. Match-drilled anchor nut plates to the two tabs.
Align and weld on two mounting tabs for the top of the pilot's instrument panel. Took way longer than it should have.
Jig upper, back center section wing spar. Attempt to locate/figure out holes that need to be made in front instrument panel for sway wires.
Gave up on trying to figure out hole locations without the actual finished pieces in place. Don't want to play this guessing game. Push until a later time.
Started drilling holes for new SL Wire Lugs.
SL Wire Lugs - finished drilling holes. Rough cut. Ready for grinding and sanding to size. Need to re-do one; cut too close to line (undercut it).
Re-making SL lugs. Made one new one.
Two more lugs made and ground to size. Actually took me 4.3hrs but that was because of a dull drill bit (not counting dull drill bit time).
Files/sand three lugs.
Study upper wing center section plans.
Drill holes for newest SL lugs.
Drill remaining holes in lugs and grind rough shapes.
File lugs. Still need to sand.
Spent 2.3hrs getting the table down and set-up in the basement workshop to start putting the upper wing center section together.
Plans - looking through both the Standard and the Radial plans. Trying to figure out what needs to be done.
more studying... of plans... looked over threads on biplane forum
more of the same...
2hrs - Tired of adding hours when all I'm doing is looking at plans and photos.
Initial set-up and alignment of spars.
Building it upside-down. Everything needs to flip. Made a BIG note and placed on work table.
Start figuring out hardware for the upper wing center section. Asked the question about match-drilling 3/4inch holes through the spars, asked on the biplane forum.
Re-ream holes for 1/4inch bolts on rear spar UWCS fittings so that I could bolt them in place and in positon for drilling/reaming 3/4inch holes.
Make drilling jig.
Drill/ream first 3/4inch hole for rear spar UWCS fitting.
continued working on opening up second 3/4 hole - need 3/4 reamer
reamed 1/4" started figuring out hardware
more figuring out of hardware
Started making extra side-rail
More work on the extra side-rail; drilling bolt holes
Drill rivet holes in extra side-rail.
Went with Tom McDowell (EAA 216 President) to a friend of his to use metal brake to bend side-rails.
Dimple rivet holes in side-rails.
Cut down rivets for side-rails.
Make plugs for spars
Cut down rivets to correct length.
Burn patterns off side-rails.
Cleans off side-rails with MEK. Riveted anchor nut plates to first side-rail.
Anchor nut plates riveted to two more side-rails.
Anchor nut plates riveted to remaining side-rails (all except extra one). Will need to drill out a few and re-rivet.
Drilling out of bad riveting. Rivet. Re-peat repeat.
Begin aligning the new side-rails/sheet metal.
Actually spent four hours on it today, but... from wasted time running up and down the steps getting tools and the 1/2 hour spent thinking if re-doing the pseudo longeron is the right way to go. Put me down for three.
Re-doing the pseudo longerons - cut/ground/filed and sanded the starboard one off. Made new stand-offs.
Aligned and tacked on new pseudo longeron on starboard side.
Finish weld stand-offs to longerons.
Trim down and fit first side-rail.
Weld on first side rail. Notched and fitted second side rail.
Trimmed and finish fit second side rail. Needed to re-drill sheet metal for alignment.