Tweaking of front/back door jam design - the supports.
More decisions about the door supports.
More - working out the support for the door and skin around the door jam.
Made one support bracket for vertical tube.
Final decision on where to put the vertical support. Practiced some welding of thin wall tubing and thin wall 4130 flat stock.
Tacked the bracket to the vertical tube. Then aligned and welded bracket/tube to upper longeron. Cut and notched horizontal tube (to support door frame tube - horizontal tube connects to one of the forward tube formers)
Un-tack and re-align door support. Re-cut and notch a new horizontal tube. Welded on vertical door support(needed to flip the fuselage for a better line on welding the bracket).
Flipped fuselage back upright. Attached cockpit skin to figure out plate for attaching hinge of door and skin to vertical door support.
Adjusted drawings for door brackets on CAD. Printed out... then rough cut, filed, drilled, sanded both pieces to completion.
Out looking at the fuselage... still thinking about this door.
Needed to set up the fuselage in a "real world" setting to really know about climbing in and out of it. Spent the day positioning the fuselage as if it were sitting on its wheels, at the correct angle. Decided that I need to open up the hole on the pilot's cockpit to get in and out.
Re-shaped the opening in the pilot's cockpit upper skin.
Figuring out the support for the sides of the rear cockpit for when I climb out and hold onto the sides for support. Also took this time to cut off and file down the one bracket I had welded on for the door support.
Notched and fitted both the starboard and port side supports.
Final fit and tack-weld of starboard and port side supports.
Finish welds of both supports. Then filed and sanded smooth the upper welds (they aren't structural) so that they won't chaff the inside of the aluminum skin.
Work on the wood transition between turtledeck and vertical tail.
Finished first wood transition. SNAP! Began making replacement wood transition.
Finished second wood transition. Started researching metal skins (.5hrs)
Research more on metal skins.
Sealed transition and cleaned up and sealed turtledeck with clear coat.
Jul 10, 12, 17, 25
Figuring out hardware for upper wing center section. Double, triple, quadruple checking.
Back to the engine mount. Figuring it out.
More confirming of hardware for upper wing center section.
More head scratching about the engine mount.
Confirm engine mount tubing. Inventory.
Still sorting through all this engine mount thinking.
Level fuselage. Cut (8) wood (psuedo rubber) bushings for the engine motor mount jig.
Cut and squared up the first two engine mount tubes for the bushings.
Cut the second two engine mount tubes for the bushings. Couldn't get the last one squared up... took forever.
Confirm and drill holes in wood bushings (pseudo rubber mounts).
All day long
ROAD TRIP: Picked up the cowl spinning! Yes!
Tried drilling/reaming out mounting bracket holes from 1/4inch to 3/8inch. NO JOY!
Again... Tried drilling/reaming out mounting bracket holes from 1/4inch to 3/8inch. NO JOY!
Made the first part of the new mounting brackets; one mounting plate.
Completed three mounting plates.
Read past blog posts about making these before. Drilled holes.
Rough cut one additional piece. Drilled holes.
More holes, more rough cutting.
Two pieces drilled and rough cut.
Two more pieces drilled and rough cut.
Two more pieces are drilled and rough cut.
Drilled holes - rough cut one blank - issue with bandsaw
Filed curves on blanks
Adjusted CAD drawings
Ditto same as above
CAD for engine mount
Begin making motor mount bracket jig.
Route 1/8inch radius on jig.
More jig making
Re-size pins for jig. Needed to cut them down to allow them to be inserted into the jig and 4130 metal and still be able to close vice.
Testing bending block jig. It works well... it's just too wide.
Made several templates to cut down bending block. It was too wide.
Cutting down the bending jig, and made a test piece to make sure that it is bending the correct width. Success!
Glued on the four center piece patterns and drilled the holes.