Rear side-formers; drilled the bolt holes in both then match-drilled the anchor nut plates for rivets.
Bent over the edge on one of the rear, side-formers.
Bent the other rear, side-former.
Drilled the holes for the filler piece that goes between the turtledeck and the frame cross member. Bent tabs and fitted to turtledeck.
Worked on the main gas tank; tweak the form, re-read the chapter in the Skybolt Manual.
Fitting up of the main gas tank. Riveting on anchor nuts to two of the side formers.
Aligned, tacked and welded on tabs on one of the upper formers.
3900 hours !
Cut new rear, side former blank and drilled bolt hole openings.
Match-drilled holes. Initial bend in piece.
Finished bending piece then dimpled holes.
Riveted on the anchor nut plates to the new rear, side former.
For two hours I worked on trying to figure out how to bend these formers without a bender. No joy !
Aligned and tacked on another row of upper former tabs.
Prepped for attaching tabs to upper, front former. Decided to change the stand-off on that former from .032 flat to .375 x .028 tubing. Cut out existing while fitting in new tubing. Tacked in place.
Weld up the front, upper former.
File/sand excess welding on front, upper former.
Tacked all except two of the remaining tabs on the upper formers.
Made holding/spacing jig for the two remaining tabs. Tacked. Then re-tacked three that I knocked off ! Sured up other rabs with new tacks.
A few sessions; welding on tabs to upper formers and cutting two blanks for the lower side-formers.
Not counting the 1/2hr looking for the paper patterns... I was finally able to glue up the hole spacing patterns on one of the blanks and file it down to a straight edge.
Filed second bottom, side former front edge. Drilled all the holes/openings for bolts.
Initial bends made in both bottom, side-formers.
Finish making bends in both bottom, side-formers. Ardorous job of taking of part of the paper pattern for riveting.
Deburr and dimple anchor nut rivet holes. Riveted in all anchor nut plates on both bottom, side-formers.
Initial work of making 30 more tabs for mounting skin; cut patterns, drilled holes.
Cut apart and ground to size all 30 additional tabs.
File/sand edges of tabs.
File and sand tabs. Trim and file tabs to size.
Started changing flat metal former stand-offs to tubing.
Filed off some of the existing weld from former, former stand-off.
More work on replacing existing stand-offs on side formers.
Filed away excess weld from previous tand-offs. Welded four stand-offs as much as I could without turning the fuselage on its side.
Still a lot of excess weld to grind/file away so I worked on that at first. Sanded it too. First set of tabs are in the jig. Need to take a few measurements before tacking into place.
Align and tack on starboard tabs to side former.
Align and tack tabs on Port side former. Finish weld tabs on starboard side former.
Weld on additional tabs.
Started fitting up upper sheet metal patterns.
More test fitting of sheet metal patterns. Placement of back windshield pattern.
Glued up and placed addtional rough patterns on the top, foward fuselage. Test fit of windshield again.
Began finish welding on the motor mounts. Welded six of the eight sides. Need to turn fuselage to get at the bottom sides.
Welding of motor mounts to fuselage.
More welding of motor mounts to fuselage
Finished welding motor mounts to fuselage. Also finished welding motor mount mounting tabs to fuselage and finished welding on a few of the upper formers that were just half-welded.
Reamed the motor mount tabs. Cut down and filed both sets of seatbelt, shoulder guides.
Cut angles on the seat belt guides.
Decisions about seat backs, tabs, etc. Thinking things through.
Decided to change up the seat backs. Worked on the new CAD drawing. Making the back like the seat pan.
Made simple jig for aligning tabs on turtledeck former (just behind the pilot's head). Aligned and tacked on all four tabs; two on each side.
Put finish weld on four tabs I tacked on yesterday. Figuring out how I really want to do the seat backs, or at least the pilot's seat back (which is the complicated one).
Drew up pattern on paper. Glued to aluminum sheet blank I cut from larger roll. Ready for cutting.
Drew up pattern for second seatback pan. Rather complicated piece.
Cut the aluminum blank, glued on pattern and drilled corner holes into blank.
Cut out first seat back from aluminum blank. The simpiler front one.
Cut out the back seat from the aluminum blank.
File edges of pilot's seat-back pan.
File edges of co-pilot's seat-back pan.
Finished filing pilot's seat-back pan.
Mark and bend long ends of seat-back pans.
Additional bends in seat back pans.
Went to fit up the seat back pans on the fuselage and saw I needed to grind off existing tabs. Ground off tabs on pilot's seat.
Ground off tabs on co-pilot's seat.
Finish filed and sanded all the tab welds I ground down/cut off.
Jig work for the first seat-back pan.
Annealing and bending all four sides of co-pilot's seat-back pan.
Cleaned glue from pilot's seat-back pan. Marked and bent the tips for riveting. FIled slots for tubes (upper area of pilot's seat back).
Trimmed top edge of pilot's seat-back to fit. Started annealing and making bends.
Tried working out the bends on the pilot's seat-back. Not working quite the way I wanted it to.
Drew-up new pattern on CAD.
Drew up new pattern on paper.
Cut blank to make new pilot seat-back pan. Glued on pattern and cut out shape.
Filed and sanded edges smooth then bent up sides.
Fit and notched seat-back pan. Initial annealing and wrapping.
Tweaking wrap. Figuring out a few things by looking at the fuselage; battery access. Attaching back seat-back pan, etc.
Figuring out how to attach seat-back pan for back seat.
Measuring, checking, drilling holes for seat-back pan attachment for pilot's seat.
Drill rivet holes in seat-back pan for back seat for anchor nut plates. Deburred all holes.
Rivet on all sixteen anchor nut plates to back-seat pan.
Figuring things out. Checking what needs to be done and need to be purchased. (2 hrs)
Making new attach bracket for the tail cone (first one is now too low on vertical stab's leading edge.
Making and fitting up the filler pieces on the tailcone. Both made. One glued on.
Glued the second filler piece on the tailcone first thing in the morning. Mounted and started figuring out the lines for the throttle quads to engine connections. Mostly research. Actually three or four hours of research.
Ground off existing tailcone bracket, filed and sanded smooth. Fit new bracket up to leading edge of vertical fin.
Aligned and welded on the tailcone bracket, plus a few additional welds that needed to be done around the bracket.
Cut most of the excess tubing left on the engine ring.
Grinding down what was left from me cutting. Still need to weld a few nicks then file.
Cleaned and filed down areas where tubing was. A little sanding and it's ready for the motor mount.
Something with the seat-back pans. Can't read my damn writing !
Anneal and bend of the tabs on the front seat-back pan. Refiguring out the battery tray and all it's brackets. Decided to re-make the tray. Will need to cut off existing one.
Cut-off existing battery tray.
Grind and file down excess tube from where battery tray was welded to fuselage.
Re-design, and making of jig for new battery tray.
Spent several hours setting up the table for the upper-wing center section. Looked over the plans and re-read how the new CAD is different than the original drawings done by Curtis. (use original drawings)
Made the jig, cut the tubing and tacked the tubes together for the re-designed battery tray.
New shelf/tray made for the battery; cut, file, sand, drill.