cut the four straps for the top of the rudder pedals.
WELD PRACTICE AGAIN !
Ground down the four straps for the rudder pedals.
Guess.... yep, more welding practice.
Yeah... more of the same... welding practice.
Looking over the plans trying to figure out the right amount of tubing to buy. Asked the biplane forum. Most plans come with a material list.
No cut list for the Radial Version of the Skybolt so I needed to figure out a way to out the length of the diagonal tubing in the frame.
Decided that I would constructed a wood mock-up of the fuselage and empennage. Cut the wood tonight for the fuselage and began marking out the
stations. Will nail together during my next work session and take measurements.
Uh... yeah.... more welding practice. Getting better with those cluster welds with
45 degree angles.
Started hammering together the mock-up of the fuselage.
Continued hammering together the mock-up. Making it in three sections so that
I can move it around. A lot slower than what I thought it would be to make this.
500 hours tonight !
Still hammering away on the mock-up.
Drawing up the fuselage structure. Figuring up that angled tubing is A LOT easier than I had thought.
It's all drawn up. Just need to find the angled measurements. Click here to find out how.
Can ya guess what I was practicing out in the garage workshop ? Yep... welding. Lookin' pretty good.
Had an additional view of the fuselage I had to draw up. Finished drawing that up on CAD. Need to take measurements for each size tubing
to come up with a material cut list for my tubing.
Figuring up the tubing list for the Skybolt. I have what I need figured,
now all I need to do is take inventory of what I have to see what I need to order.
Took inventory of the 4130 tubing I had here. Need to place that order now.
Getting ready to weld the rudder pedals. A little practice welding the flat caps that go onto the ends of one tube for each rudder pedal.
Good solid welds. Not as difficult as I thought it would be. Not real pretty though.
More practice with welding caps on the ends of tubing. Also another practice weld on
a 45 degree weld joint. Consistently good with the welding. Caps could look better though.
First time at drilling holes into metal. Drilled under-size then reamed to size. Drilled the holes
in the four fittings that connect to the rudder cables. I also had to sand the edges and the face of these to get out the marks I made with the grinder. Sanded these on the table-top belt sander.
a 1 1/8" holesaw drill to cut out the 7/8" diameter .100
4130 caps. What with me having to change out the bandsaw
blade (don't buy Harbor Freight blades) to cut the metal blank for the 8 pieces, I worked on
this for 1.3 hrs only to have cut 4 of them out.
Cut the additional 4 circular blanks out, plus one for a test weld. Took a close look at
the drawings and saw that the tubing for the rudder pedals are 7/8 x .056 not .049.
Dry run on welding up a rudder pedal. Turned out
Received tubing in for the Rudder and Brake Pedals. Started cutting pieces to size.
Vacation day. YAHOO ! get to work on the plane. Cut ALL of the parts for the
Rudder Pedals. Still need to finish trim three pieces and then it's ready to GET WELDED !
Trimmed the three pieces down to size. Welded on all eight caps for the horizontal pieces on
the Rudder Pedals. First actual piece of the plane that I welded up. Ground down excess weld and finish sanded with 150 grit.
Tack welded up most of the rudder pedals. I haven't drilled the holes into the horz. tubes
that connect to the brake pedals so I didn't tack those on yet. Pretty much welded up one of the rudder pedals.
Welded up the main welds on the remaining three rudder pedals. Main meaning, the vertical tube with the
lower horizontal tube and the 2" tube to the vertical tube. Moving right along...
Set about drilling the holes in the horizontal tubes that connect to the brake pedals.
Got only two drilled. woohoo... big yippee... They wouldn't chuck in the microlathe for reasons I won't go into so I had to figure how I was going to
center them on the drill press. End result... two holes drilled. Disappointing night.
Last night... my mistake. I picked up the wrong metal cutting drill bit. BIG difference between a standard and one of those cobalt ones.
Anyways... drilled the rest of the holes in the horizontal tubes. Looked at them and decided I wasn't too happy with the centering of the holes on the caps. Re-cut new caps and have cut additional
tubing to re-make the four pieces. They're all cut ready to weld together again.
Welded all eight caps on the ends of the four horizontal tubes. Time to put up the tree so it looks like I'll be
grinding these down tomorrow and drilling the holes in them.
Ground down, drilled, and reamed holes in both ends of two
Drilled and reamed the remaining four holes in the
Cut the tubing for front brake pedals. Tomorrow I'll cut the
other brake pedals and possible welding up of them.
Cut the additional tubing for the pilot brake pedals including the center tube which
has a bracket that connects to my Cleveland brakes.
Tacked together all four brake pedals (unhappy with the squareness of one - will either
pull apart and re-tack or cut new tubing. Welded up both passenger brake pedals (eight welds.)
Hacksawed apart one pilot brake pedal and retacked together. Welded up one
pilot brake pedal.
Hooked up the two new tanks. Welded up an additional brake pedal.
Filed down and finish sanded with 180 grit sandpaper the two pilot brake pedals. Filed off
excessive weld. Primered them.
Filed down excess welds on another brake pedal. Finsh sanded with 180 grit. Primered them.
Looked at my finished pedals and was unhappy with the "squareness" of one of the rudder pedals. Set about cutting all new tube,
tacking and then welding the brake pedal together. Gotta love trying to be a perfectionist.
Filed and finish sanded the last brake pedal. Primered it too.
Tacked welded the fittings that connect to the rudder cables. Welded the top edge of the horizontal tubes to the rudder pedals. Banged (bent) horizontal tubes per plans.
Welded up one entire rudder pedal.
Welded up two rudder pedals.
Bent and drilled brackets that are connected to the pilot's brake pedals (still need to ream after welding the two pieces together. Drilled and reamed holes in 12 small brackets that get welded to
the brake pedals.
Welded up the last brake pedal then filed and finished sanded with 180 grit.
Laid out the landing gear bungee truss.
Filed and sanded edges of all tabs that go on the brake pedals.
Positioned and tack-welded all tabs on the brake pedals.
Put finish welds on ALL tabs. Drilled and reamed holes completely
through the brackets that connect to the small vertical tube on the pilot's brake pedals, welded them on as well.
Finished the rudder/brake pedals !
Sanding down and putting primer on the four pedals
Looking at the plans and what I drew up for the bungee truss area. The R version calls for
a shock strut as opposed to the Standard versions bungee system. The shock strut isn't even proven. Still sorting this out.