CADing, thinking, re-CADing, more thinking, re-re-CADing
Jan 13 - 18
Muling things over.
Markings for the holes on the main fuel tank wrap.
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
A lot of tuck shrinking learning going on.
GOOD Practice. Annealing and tuck shrinking.
Tuck shrink testing
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.
Cut and glued up oak wood I purchased... to make new forming jig for end-caps.
Routing top piece of new form.
More work on tank end-cap jig/form. Checking busings for straps.
Glued bottom form for end-cap jig. Started cutting/reaming bushings for straps.
Started routing bottom form - blew out two bearing bits! Wood putty repair of form started.
Drill holes, routed shape of end-cap form (spending a lot of time on making this form!
Set-up for practicing tuck shrink... again. Cut and routed an additional corner for practicing.
More practice - tuck shrinking
Practice bead rolling.
Marking vertical lines on form for bead rolls as pattern for figuring out where I can/can't roll.
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.
Tuck shrinking the first corner on the main fuel tank. Also worked on the bushing for the strapping of the tank.
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.
Tuck shrinking on the second corner, and finished up the (8) bushings for the strapping of the tank.
Finished practice on test end-cap. Started designing jig for bead roller. 100 yard stare...
Received aluminum VIA UPS. Drilled positioning holes, traced shape of blank. Marked blank with bead lines.
Cut wood and glued up jig for bead roller.
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.
Cut out pattern of first end-cap. Started annealing and tuck shrinking.
Continued tuck shrinking.
More tuck shrinking.
and... more tuck shrinking of first end-cap.
More... annealing and tuck shrinking of first end-cap.
Finished shrinking first end-cap. Prepared jig for end-cap number two.
Started getting blank ready for number two end-cap; marking, drilling, etc.
Bead roll and cut out blank for 2nd end-cap. Started edging and prep for annealing.
Annealing and shirking begun on 2nd end-cap.
More of the same... work on the 2nd end-cap.
More work tuck shrinking the 2nd end-cap. Almost there.
More tuck shrinking on the second end-cap.
Finished tuck shrinking second end-cap.
Cut jig pattern for trimming down end-caps. Rough-cut both end-caps close to depth.
Trim down end-cap A closer to final depth.
Filde down A to final depth.
Trimmed then filed to depth, end-cap B. Cut off excess aluminum slag from B.
Sanding and filing of end caps.
Finished beading... then... Wasn't happy with the bead locations on the wrap. Re-looking at where beads and fitting are to be located.
CADing of new bead locations.
Playing. Put the stringers on to see how the shape of it. Wrote list of immediate things I could do on the fuselage.
Open up holes in flooring tabs.
Align and drill holes in back heel trays/flooring.
Rough-cut new wrap for main fuel tank.
Covered backside of aluminum blank for protection. Marked new bead lines.
Ran all new beads. Ready for marking and drilling holes.
Masking fuel tank.
Cut two larger holes in fuel tank wrap; fuel opening, and fuel gauge sensor.
Drill additional holes in fuel tank wrap.
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.
Drilled front flooring screw holes
Figuring out the Dzus fasteners locations on the turtledeck door.
File openings where the brackets slide into the back of turtledeck door.
Search for "L" drill attachment. No joy!
Found "L" attachment! Drilled and de-burred remaining holes in front flooring.
Thinking through the bracket that will allow the turtledeck door to attach to the turtledeck.
Figuring out the bend for the bracket by doing a test bracket.
Research on the Dzus fastner for the turtledeck door. YIKES!
Cut and file tabs/brackets for both Dzus fasteners for the turtledeck door.
Jun 29 - Jul 4
Figuring out the correct Dzus fasteners and springs to order for the turtledeck door.
Figuring out Dzus fasteners.
Still working out Dzus fasteners.
Dzus pattern laid out on turtledeck door.
Drilled holes for Dzus fasteners in brackets and turtledeck door.
Fitting up of Dzus fasteners
Aligned tabs for Dzus fasteners.
Match-drilled back plates for Dzus fasteners. It works!
Match-drilled and riveted on the anchor nut plates for the starboard side-panel.
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.
Fit up starboard stringers.
Work on the stringers.
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.
Cut and drilled new stringer. Figured out the old plan was the way to go.
Drilled stand-off holes to size and deburred.
Drilling holes in stringer stand-offs for the rivets.
Drilling more holes in stringer stand-offs for the rivets. Also beveling the holes to accept the rivet heads.
Riveted on 8 anchor nut plates.
More riveting... more anchor nut plates.
Drilling of rivet holes on port side..
Beveling of rivet holes. Final 8 stand-offs for sides.
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.
Match-drilled holes in belly stand-offs for anchor nut plates.