Re-do, side instrument panel; drill out round-head rivets, counter sink for holes for new rivets. Re-attach anchor nut plates with new rivets.
Fitting up and tweaking of starboard side stringers.
Port side stringers. Re-make of the center stringer. Fitting up and tweaking of the two additional stringers.
Fitting up and tweaking of belly stringers. Will probably re-make one of them.
Figuring out the 2 outer belly stringer rear connections.
Staying with the full length outer belly stringers. Otherwise it doesn't flow right. Notched, or un-notched?
Match-drilled new starboard belly stringer. Still figuring out exactly where to connect the rear point.
Re-do of port belly stringers. Figured out the rear attaching!
New middle belly stringer cut and match-drilled.
CAD up brackets for rear-end of port and starboard belly stringers.
Made (2) brackets for rear-end of port and starboard belly stringers. Kind of figured out the direction I want to go with it all.
Cut the .050 plate to support the rear port and starboard belly stringers. Test fit after cutting off the two existing tabs I had there originally to connect the rear of the stringers to.
Figured out where to put the back belly attach bracket. Aligned and marked on fuselage.
Made two new tabs.
Rounded top of tabs to reduce weight. Figured out angle of backet on fuselage - 5.5 degrees to the bottom longeron.
Welded both tabs onto mounting plate.
Aligned and welded (top side) of plate to fuselage. Still need to flip it and do the bottom welds.
Belly stringers - marked and drilled holes for attaching stringers to new rear attachment. Attached all belly stringers on biplane.
Looking up information about the straps for the main fuel tank.
Measure and mark locations for straps. Simulated with fabric straps to make sure things would fit as planned.
Clean up bushings. Measure again for alignment of bushings for straps. Made up simple jig to hold bushings in place.
Placed bushing jig next to side of tank and saw that I was off (long story). Re-made jig and tests positive this time!
Align jig in fuselage. Square it up. Ready for tack welding!
Tack weld main tank support bushings onto upper longeron. I now smell like a camp fire.
Strip the fuselage of stringers and firewall so that I can access the bushings without any interference.
Welded on all eight bushings for the main fuel tank straps.
Check alignment of bushing for fuel tank straps. Reamed.
Cleaned edges of strips for straps. Made one "test" slot. Made adjustments based on the test pieces then made the first good slot for the straps.
Drilled, cut and filed two more slots.
Made last slot. Re-made one slot becuase of cutting off the end at the wrong location.
Flipped fuselage. Welded up all four slotted ends. Fitting up of the first tank strap.
First tank strap measured for size, slotted, welded, and bolted on. Bam!
Second tank strap measured for size, slotted, welded, and bolted on. Bam!
Third tank strap measured for size, slotted, welded, and bolted on. Bam!
Forth tank strap measured for size, slotted, welded, and bolted on. Bam! Now all I need to do is put the rubber strap covers on the straps and I'm finished with the tank supports.
CADing the scoop out... figuring it out; shape and how to make it.
Figuring out how to go about making the increased bend on the seat pans and backs.
Anneal and bend four flanges on pilot's seat pan. Marked for drilling.
Mark, drill, and de-burr all screw holes in pilot's seat pan.
Match-drill and de-burr all rivet holes for anchor nut plates in pilot's seat pan.
Riveted on all anchor nut plates onto seat pan.
Countersunk existing rivet holes on instrument panel brackets.
Riveted on anchor nut plates to top brackets for instrument panel. Spent the rest of the time trying to figure out how I'm going to reach the rivets for the side brackets. I can't.
Hand tapped rivets in existing holes on brackets and filed them down... to file in holes.
Spent close to an hour and a half on this. .4 hrs to set up the intrument panel and drill the top mounting hole. One hour of trying to figure out the best way to reach the rivet holes before drilling those rivet holes. Only way to do it is to open up the jaws of the riveter then twist the jaws to the right hight and then squeeze. Maybe?
Drilled holes for anchor nut plate on top of the instrument panel. Just three holes. Squeezed the rivets for attaching. Checked alignment on fuselage.
Match-drilled rivet holes for 8 anchor nut plates. Counter-sunk all 16 holes. Painted surface for rust prevention before riveting on nut plates.
Riveted on 8 anchor nut plates to throttle mounts.
Spent 1.3hrs on writing down and figuring out turtledeck mount and other stuff... again.
More thinking of tabbs to mount turtledeck, the first ones I made and welded on are too short. CAD'd up new tabs with hole location using 5/8" wide x .070 4130 steel strips.
Printed out patterns for new turtledeck mount brackets, drilled machine screw holes, match-drilled rivet holes, counter-sunk rivet holes, deburred.
Cut apart tabs. Rounded tops - filed and sanded.
Measured all 10 tabs for length with turtledeck on fuselage. Cut down to lenght.
Weld on six turtledeck mounting tabs.
Cut, grind, sand, eight existing tabs off of fuselage. Were there previously for mounting the turtledeck.
Final four tabs welded on. Cleaned up some of the left over welds from the tabs I cut off.
Aligned and clamped turtledeck in position for match-drilling holes with tabs.
Match-drilled turtledeck to mounting tabs. Took off tailcone section. Enlarged holes. Reattached to match-drill holes in tailcone section. Still need to hand-drill one hole in front-right section of turtledeck. Could not reach with any tools. Marked for drilling.
hand-Drilled remaining holes in turtledeck. Checked for fit. Reamed out the five tabs that are at the rear of the tailcone. Ready for monadnock clip nuts.
Riveted on (10) anchor nut plates on the turtledeck tabs.
Flipped fuselage and prepped for belly scoop. CAD'd up what I needed to transfer front belly scoop former onto plywood. Welded up new pipe on front of rotisserie (thing I use to spin the fuselage). I actually had two hours on it today... but not putting down the flipping and the welding of the rotisserie.
More sizes on CAD for transfering to ply.
Sketch scoop dims onto display board.
Transfer that pattern onto plywood.
Cut first ply former on a sheet of ply I thought was going to work well. Purchased from Home Depot. The outer layers splintered pretty bad. Not a wise choise of material. Found a sheet of 1/8inch ply and transfer pattern... then cut. It's a keeper.
Attach belly stringers. Fit up of lower belly enclosure.
Re-do of that same lower belly enclosure. Wasn't happy with it.
ANOTHER re-make of that SAME lower belly enclosure.
Tweak the fitting of that 3rd belly enclosure.
Made fourth and final belly enclosure.
Cleaned up belly enclosure; deburred, cleaned edges.
Drilled and cleaned the holes to mount the enclosures.
Marked and drilled holes in stringer stand-offs for belly enclosure.
Deburred all enclosures.
Match-drilled rivet holes for anchor nut plates for enclosures.
Match-drilled four additional rivet holes for anchor nut plates. Counter-sunk all rivet holes for enclosures.
Two new eclosures mounting brackets. Made to replace two that were too small.
Trimmed down two new tabs. TOO BIG. About 1/2 the size and 1/2 the weight now. Welded one side of them on belly former. Still need to weld other side.