CADing, thinking, re-CADing, more thinking, re-re-CADing
Jan 13 - 18
N/A
Muling things over.
Jan 19
.6hrs
Markings for the holes on the main fuel tank wrap.
Jan 20
2.5
Cut additional form for making the main fuel tank end-caps. Locked the first aluminum blank in place and started banging away to form the end. Only about 1/4 of the way there.
Jan 21 - Feb 9
N/A
A lot of tuck shrinking learning going on.
Feb 10
3hrs
GOOD Practice. Annealing and tuck shrinking.
Feb 11
1hr
Tuck shrink testing
Feb 18
1.1hrs
More shrink testing. Crushed edge of main tank form. Will need to repair and make another form for practicing and for the final end-caps. Maybe oak wood.
Feb 20
1.5hrs
Cut and glued up oak wood I purchased... to make new forming jig for end-caps.
Feb 22
1.2hrs
Routing top piece of new form.
Feb 23
2.5hrs
More work on tank end-cap jig/form. Checking busings for straps.
Feb 24
2.7hrs
Glued bottom form for end-cap jig. Started cutting/reaming bushings for straps.
Mar 2
1.3hrs
Started routing bottom form - blew out two bearing bits! Wood putty repair of form started.
Mar 3
3.3hrs
Drill holes, routed shape of end-cap form (spending a lot of time on making this form!
Mar 4
.7hrs
Set-up for practicing tuck shrink... again. Cut and routed an additional corner for practicing.
Mar 9
2.4hrs
More practice - tuck shrinking
Mar 10
.8hrs
Practice bead rolling.
Mar 15
.5hrs
Marking vertical lines on form for bead rolls as pattern for figuring out where I can/can't roll.
Mar 16
2.6hrs
Finish up form by drilling holes for alignment pins. A few additional bead rolling practices. Bead rolled the one aluminum blank after marking lines. Started banging down ends to begin the process of tuck shrinking.
Mar 17
2.6hrs
Tuck shrinking the first corner on the main fuel tank. Also worked on the bushing for the strapping of the tank.
Mar 22
2.9hrs
More... tuck shrinking the first corner, then started the second corner on the main fuel tank. Also worked on the bushing for the strapping of the tank.
Mar 23
2.7
Tuck shrinking on the second corner, and finished up the (8) bushings for the strapping of the tank.
Mar 24
2.4hrs
Finished practice on test end-cap. Started designing jig for bead roller. 100 yard stare...
Mar 27
.4hrs
Received aluminum VIA UPS. Drilled positioning holes, traced shape of blank. Marked blank with bead lines.
Mar 29
.6hrs
Cut wood and glued up jig for bead roller.
Mar 30
1.7hrs
Jig needed to be re-worked to be useable. Cut and glued additional pieces. Came back after glue dried and ran the beads for the first main fuel tank end-cap.
Mar 31
3.1hrs
Cut out pattern of first end-cap. Started annealing and tuck shrinking.
Apr 1
1hr
Continued tuck shrinking.
Apr 2
1.1hrs
More tuck shrinking.
Apr 5
.7
and... more tuck shrinking of first end-cap.
Apr 7
2.7hrs
More... annealing and tuck shrinking of first end-cap.
Apr 10
1.4hrs
Finished shrinking first end-cap. Prepared jig for end-cap number two.
Apr 12
1.8hrs
Started getting blank ready for number two end-cap; marking, drilling, etc.
Apr 14
2.3hrs
Bead roll and cut out blank for 2nd end-cap. Started edging and prep for annealing.
Apr 17
.8hrs
Annealing and shirking begun on 2nd end-cap.
Apr 19
2.7hrs
More of the same... work on the 2nd end-cap.
Apr 20
.9hrs
More work tuck shrinking the 2nd end-cap. Almost there.
Apr 26
2.6hrs
More tuck shrinking on the second end-cap.
Apr 28
.4hrs
Finished tuck shrinking second end-cap.
May 5
2.9hr
Cut jig pattern for trimming down end-caps. Rough-cut both end-caps close to depth.
May 6
1.7hrs
Trim down end-cap A closer to final depth.
May 8
1hr
Filde down A to final depth.
May 10
1.5hrs
Trimmed then filed to depth, end-cap B. Cut off excess aluminum slag from B.
May 11
.7hrs
Sanding and filing of end caps.
May 12
3.8hrs
Finished beading... then... Wasn't happy with the bead locations on the wrap. Re-looking at where beads and fitting are to be located.
May 13
2.5hrs
CADing of new bead locations.
May 14
.9hrs
Playing. Put the stringers on to see how the shape of it. Wrote list of immediate things I could do on the fuselage.
May 15
1.0hr
Open up holes in flooring tabs.
May 17
1.4hrs
Align and drill holes in back heel trays/flooring.
May 18
.9hrs
Rough-cut new wrap for main fuel tank.
May 19
2hrs
Covered backside of aluminum blank for protection. Marked new bead lines.
May 24
1.9hrs
Ran all new beads. Ready for marking and drilling holes.
May 26
.6hrs
Masking fuel tank.
May 29
.9hrs
Cut two larger holes in fuel tank wrap; fuel opening, and fuel gauge sensor.
May 30
.9hrs
Drill additional holes in fuel tank wrap.
May 31
5.4hrs
More holes in wrap, and prep wrap for welding. Bending of air vent tube. Pulled off plastic wrap (protecting from scratches), fitting up of sides to wrap, and cut to fit.
Jun 10
1.5hrs
Drilled front flooring screw holes
Jun 11
1.1hrs
Figuring out the Dzus fasteners locations on the turtledeck door.
Jun 14
.7hrs
File openings where the brackets slide into the back of turtledeck door.
Jun 20
N/A
Search for "L" drill attachment. No joy!
Jun 24
1hr
Found "L" attachment! Drilled and de-burred remaining holes in front flooring.
Jun 25
1hr
Thinking through the bracket that will allow the turtledeck door to attach to the turtledeck.
Jun 26
.9hrs
Figuring out the bend for the bracket by doing a test bracket.
Jun 27
1hr
Research on the Dzus fastner for the turtledeck door. YIKES!
Jun
28
.4hrs
Cut and file tabs/brackets for both Dzus fasteners for the turtledeck door.
Jun 29 - Jul 4
N/A
Figuring out the correct Dzus fasteners and springs to order for the turtledeck door.
Jul 8
1.3hrs
Figuring out Dzus fasteners.
Jul 13
1hr
Still working out Dzus fasteners.
Jul 24
.8hrs
Dzus test
Jul 26
1hr
Dzus pattern laid out on turtledeck door.
Jul 31
1hr
Drilled holes for Dzus fasteners in brackets and turtledeck door.
Aug 1
1.9hrs
Fitting up of Dzus fasteners
Aug 5
.6hrs
Aligned tabs for Dzus fasteners.
Aug 7
.9hrs
Match-drilled back plates for Dzus fasteners. It works!
Aug 18
1hr
Match-drilled and riveted on the anchor nut plates for the starboard side-panel.
Aug 19
.5hrs
Fitting up of the stringers. Making sure that they are correct before I start to drill and attach anchor nut plates for easy attaching of stringers to stand-offs.
Oct 8
1.2hrs
Fit up starboard stringers.
Oct 9
1.1hrs
Work on the stringers.
Oct 14
1.2hrs
Work on the port side stringers. Tried drilling through the one stringer to match-drill to stand-offs. Messed it up. Found 12ft stringer material to make a new one.
Oct 15
1.1hrs
Cut and drilled new stringer. Figured out the old plan was the way to go.
Oct 16
1hr
Drilled stand-off holes to size and deburred.
Oct 17
1.3hrs
Drilling holes in stringer stand-offs for the rivets.
Oct 18
2.6hrs
Drilling more holes in stringer stand-offs for the rivets. Also beveling the holes to accept the rivet heads.
Oct 20
1.1hrs
Riveted on 8 anchor nut plates.
Oct 21
1.5hrs
More riveting... more anchor nut plates.
Oct 22
.7hrs
Drilling of rivet holes on port side..
Oct 23
1.3hrs
Beveling of rivet holes. Final 8 stand-offs for sides.
Oct 25
1.4hrs
A bit of this was time to flip the fuselage on its side. The rest of the time was enlarging the bolt holes. Still need to match-drill rivet holes and attach nut plates.
Oct 26
1hr
Match-drilled holes in belly stand-offs for anchor nut plates.