Riveted the second 1/2 flange on the firewall. Still need to squeeze the round head rivets on both halves.
Deburred the holes in the exhaust port area of the firewall then filed down the stainless steel that was overhaning in that area.
Riveted the three flanges to enclose the exhaust port area then went back and riveted on the round head rivets.
Filed stainless steel overhanging the perimiter of the firewall. Test fit up to fuselage.
Cut new angles on the seat backs so that they would frame the perimiter of the seat backs.
Measured out and glued up the rivet pattern for seat back frames. Drilled starting hole with centering bit for all holes.
Drilled and deburred holes in four flange pieces.
Match-drilled side flanges to seat back frame.
Spent three hours shaving down rivets.
Shaved more rivets. Tried riveting but rivets kept squishing on an angle.
Riveting frame on seat back. Not easy to do on this part. Part kept wanting to twist when doing the squish. I'm only happy with two out of all the ones I've done. Spent over three hours on it tonight trying to figure out what is what.
Riveting the "L" flange to the seat back. Pretty damn happy with the riveting.
Match-drill top and bottom flange to pilot's seat back.
Riveting the "L" flange to the top of the pilot's seat back.
Prepping the co-pilot's back seat for rivets; cleaned off pattern from outside edges of seat back then started fitting up the "L" flanges to it.
Riveted the lower "L" flange on the pilot's seat back.
Drilling holes in one long seat back flange.
Drilled holes in second long seat back flange. Started to match-drill flanges to seat back.
Finished match-drilling both flanges to seat back then began riveting them on.
Filed down an additional 135 rivets. That should do it for the seat backs.
Continued riveting the first side flange on the seat back.
Riveted the entire length of the second vertical edge on the second seat back. A lot of seconds there...
Drilled the holes in top and bottom seat back "L" flanges. Deburred them too.
Match-drilled top and bottom flanges to the co-pilot's seat back. Deburred the holes.
Riveted the two remaining "L" flanges onto the second seat back. Just a few odds and ends to do on them and they are finished !
Cleaned off remaining glue from the second seat back. They look beautiful. Also glued down and cut out the first seat pan.
Drew up the new pattern for the seat pan. Glued it on the sheet of aluminum. Cut out the blank.
Trimmed blanks closer... deburred and sanded smooth the edges of both seat pans.
Made jig for bending sides on seat pans then bent them up.
Bent the edges on the seat pans where I will be riveting them onto the seat frames. Spent an addtional 2.5hrs on cleaning off the paper patterns!
Spent about 3hrs on the build tonight... cleaning off excess glue and then taking the film off the back-side of the seat pans. Nothing I'm putting down as far as hours on the build though.
Practicing annealing aluminum and then wrapping around seat frame. No hours put on build.
Final fitting and trimming of first piece. Figured out the jig for holding the seat pan at the correct height.
Began the bending process. One boo-boo. One good bend. Made this into a practice piece.
Trimmed second seat pan for additional cuts that needed to be made for fitting. Still need to file it to the line.
Second try on annealing and bending the sides of the seat pans. Second try a SUCCESS ! Still need to tweak the bends.
Spent a few hours figuring out and cutting out the patterns for the airfoil shape for the main landing gear.
Made jig to square up rear tube attachments then square them up. Issue with glue, gluing jig in second tube. What a PIA. A little MEK and I got it out.
Airfoil shapes for main landing gear. Made the wood template. Bent, cut and filed to fit all eight pieces of 4130 .375 x .o28 tubing.
Drew up the pattern for the top airfoil for the main gear. Bent and cut the four pieces and ground them down to size. Wasn't happy with a few of the ones I did earlier and re-made them.
Drew up the paper pattern for the first (actually third) seat pan and cut out the blank from the 4x10 sheet of aluminum.
3500 hrs !!!
Two session on the main gear today. Final fit of the airfoil shaped tubes and then tack to the gear.
Cut the pattern out for the second (third actually) seat pan blank. Modified the corners: re-drew the side lines to meet at the bottom of the stress relief hole instead of intersecting the sides. Better look.
Welding on all six airfoil shapes to the main landing geaer.
Filing edges of second seat pan blank to line. Still need to deburr and sand.
Check and file down any of the welds that need filing down on the airfoil shapes on the main gear.
Initial bends on seat pans. Clean off pattern. Put into seat frame... mark where I need to cut out back a little bit more. Cut out back. Anneal. Bend over seat frame.
2015 Total: 538.1hrs
Trying to make the corners of the first seat pan look like the second seat pan.
Re-making the first seat pan. Got it to the point of having the shape cut out and filed to the line. Still need to deburr, bend, anneal and wrap around the seat frame.
Deburr and initial bending of the seat pan.
Clean off paper pattern from seat pan so that I can heat it to anneal.
Anneal and wrap seat pan around seat frame.
Figuring out the look of the back cockpit sheet metal and opening. I have the first iteration cut-out and taped in place.
Do you put all that time down that you think of what you need to do? If so... I'll need to start logging my drives to and from work. Spent a lot of time thinking of what I'll be doing with the sheet metal around the cockpits. Decided to make doors on the port side for easy entry.
Made a progression of one pattern for the former for the rear pit. Final iteration was a pattern made of masonite. Looks like this will work.
Bend former for rear pit overhang.
Confirmed that the shape and size of former for rear pit was correct. Cut to size and tacked onto fuselage.
Figuring out the faceted windshields. Ideas right now... not actual work on the biplane.
Figuring out the pilot's faceted windshield shape. Made two patterns.
More work on the rear windshield. Firmed up the shape.
Work on the rear instrument panel. Figuring out the final shape/size.
More work on the instrument panels. Cutting and fitting up of pattern to fuselage. Final pattern for the back pit ? Still working on the panel for the front pit.
Back pit's instrument panel: cut out final pattern shape. Transferred to wood and cut jig out. Cut rough blank out of aluminum.
Match-drill aluminum blanks to wood jig. Routed the rear cockpit's instrument panel's face plate and back plate.
Route front, raised plate on rear instrument panel. Cut out cirlces and played with the look of the instruments on the panel. Spent 2.5hrs... only putting down 1hr.
Measuring and marking holes for instruments
Cutting first two holes in the center, back pit instrument panel. Brutally slow.
Cut the remaining three holes in the center, back pit instrument panel. Got it down from 1hr a hole to 1/2hr.
Two more holes; holes in the back pit's main panel.
Drilled the additional holes in the rear cock-pit's instrument panel. Figured out, measured and notched both "U" channels for supporting the face plate for said instrument panel.
Notched out the back-pit's main intrument panel.
Fine tuning the front pit's instrument panel shape.
Drilling and notching flanges for the center, curved sections of the back instrument panel. .
Made the wood jig for routing the front instrument panel pieces.
Routed main panels for front cockpit's instrument panel.
Routed the face plate for the second instrument panel.
Spent all morning re-thinking what instruments to put in the panel. Made a big change to the look of it. Re-routed the back pit's face plate. Cut (6) 2 1/4inc holes.
Cut final four holes in instrument panels. Notched the front cockpit's face plate support channels.