MEK-off the pattern from the battery tray. Clean it up. File-down the left-over weld on battery tray frame.
Weld on new tray. Warpping. Cut off new tray.
Cut new tray and file off weld slag from frame. Will wait to weld on new tray until weight and balance done. Still need to weld on frame to fuselage.
Made two connecting rods to connect front and back throttle quads.
Weld ends onto throttle interconnects. Fitted and notched battery tray in place.
Tacked battery tray frame to fuselage (front points) and initial measuring of upper support tubing.
Notching and fitting of upper support tubing or battery tray. Tacked onto tray and fuselage.
Started finish welding battery tray to fuselage.
Finish welding on battery tray.
Mock-up of measurements for upper wing to test out sway wires. Looks like they'll be coming into the front pit pretty far.
Jan 9 -13
Figuring out the wing center section. Drew up the SL Wire Lugs that I'll need for build.
Went over to Mike's house. Bent up the 4130 sheet metal side-formers.
New jig support for upper wing center section spar. Test for sway wires.
Cut off upper, outer former supports. Started grinding/filing down excess welds.
Finished filing excess welds from tubing. Cut and fit two new supports. Ready for welding.
Weld vertical supports for upper former for station 24. Filed welds then sanded.
Started looking at sheet side formers for skins. Decided that I needed to cut a sheet metal blank for fitting and figuring.
Cut additional sheet metal blank for figuring out location of metal former supports. Started fitting/figuring out skin and former placement.
Tweaked the side formers... making them as straight as possible.
Started aligning the side formers. Made a jig out of the sheet metal to hold the side former while aligning with the next one behind it. Need to do something with the support tubes I have welded in place.
Notching the pseudo port upper longeron to allow anchor nut plates to fit in close.
Making washers to weld over notches.
More work on washers... grinding down to size.
Weld washers to pseudo longeron.
File off excess weld build up around 3 washers
File off excess weld build up around 2 washers
Finished filing ""cups" on Starboard side. Started setting up the sheet metal for alignment of holes on Port side.
Filed five holes for recesses. Cut out five blanks for cups to cover holes.
Make cups and weld in place.
File five additional holes.
Weld in and file cups smooth.
Four more notches for cups in forward, Starboard, pseudo longeron.
Cut four additional cups. Welded onto forward, starboard side.
File smooth four more cups on pseudo longerons.
Filed open the remaining four holes on the forward port side.
Grind remaining cups to size. Weld onto longeron. File welds on all remaining cups.
Cut off first two ends. Cut four caps from .o32 4130.
Cut off remaining two ends.
Weld on caps. File down weld on first cap.
Filed excess weld from the three remaining caps. Ready to test fit the sheet metal skins again.
Test fit first sheet metal skin (starboard side). Small gap on rear upper former. Cutting small filler piece to weld in.
Make second filler. Fit, tacked... then welded both onto former.
4100 hours !
Former is warped. Over thought how to fix. I don't want to fix this. Traced firewall for new former pattern. Ordered new tubing for former.
Cut off old tabs. Found tabs I made while looking for pattern to make new tabs.
Bent new former.
Cut former to size. Trying to figure out how I want to position and weld on new former. Cut curve off of old former and using vertical supports to position new former (still need to tack, cut new supports, and then weld in place).
New upper former checked for alignment then tacked into place. Cut the existing vertical former supports off and filed and sanded areas.
Aligned and welded on the vertical supports for the new upper former.
Align and tack on all nine anchor nut tabs onto the new upper former.
Weld tabs onto new upper former.
Flipped fuselage. Began to look at forward belly formers and areas that would need to be addressed around the openings for the landing gear.
Figuring out what to do with the belly former. Cut off the forward one. Cut down the sides of the second one back. Will re-make the forward one. Modify the second one back.
Figuring out the second former still. Need to make it so that the fabric can attach from lower longeron to lower longeron.
Fitted, notched and filed tubes for modified belly former. Tacked port side tubes into place.
Cut, fitted and tacked starboard side tubes into place. Completed all welds on all four areas to be welded. Need to make and weld on anchor nut tabs.
Drill holes in sheet of tabs. Deburr.
Cut out tabs and grind front curve on each.
File and sand smooth - edges on all tabs. Bend 45degree angle on them.
Trimmed tabs to length.
Bending/shaping the new belly former.
Aligned, adjusted, tacked on new belly former.
Finish weld belly former at station 10.o. Align and tack tabs on new belly former.
Align and tack on six remaining anchor nut tabs.
Tack on two additional tabs and finish weld all tabs.
Cut-off/trim former ends. Weld closed. Think through next step - align and weld on side formers.
Started fitting up starboard side-former. Twernt easy to get at... at first.
Two sessions; Tack and weld on starboard side former (with anchor nut plates). Most of this time is figuring how to get at the side former for tack welding it, next session cut/trim former for port side - then tack and weld into place.
Started figuring out the fit of the 2nd side-former for sheet metal skin.
More work on the 2nd side-former fitting.
Decided that I needed to have the first skin in place before I could position the second one correctly.
Fit and cut/trim 2nd side-former of second station section. Make sense ?
Cut aluminum skin test panel. Used for forward section. Fit first of two second side-formers in place.
Tack/welded 3rd side-former with anchor nut plates. Fitted tack/welded 4th side-former for attaching the sheet metal skin.
Fitted/trimmed the two remaining upper side-formers.
Cut an additional alignment skin. Test fit for remaining set of side formers. Former runs past two parallel upper formers than angles to the remaining. Need to make an additional alignment skin before aligning and tacking.
Cut aluminum sheets for aligning third set of side-formers. Started drilling attaching holes and fitting into place.
Tweaking the fit before tacking/welding 3rd set of side formers on. Not liking what I have. Rethinking it.
Aligned, tacked and welded on the final set of side-rails (wrong to call them formers ?).
Checking rails-to-former fit with aluminum sheet. Thinking through the windshield.
Started on the windsield then decided better. Flipped fuselage. Measured for pseudo bottom longeron in first bay. Cut side-rails to length. Cut .875 x .o35 tubes to length. Made washers to cap ends of both tubes.
Made stand-offs for both pseudo longerons; cut tube and lathed square and to size.
Welded on the stand-offs onto the pseudo longerons for the belly area.
Aligned and welded on false belly longerons.
Final check for the fit of the side-rails on the false belly longeron and they'll work how they are. Flipped the fuselage to align and weld on the final set of side-rails to the false belly longerons. Slightly bent one of the upper side-rails. Will need to tweak it back out. Looking closer to the other side-rails, decided I wasn't happy with three of them and the slight bow they have. Deciding on what to do with those. In the meantime started creating a rotisserie to use for spinning the fuselage with the firewall in place. Created CAD for possible large tabs for use instead of side-rails. Then... thought of grinding off center welds on side-rails, clamping straight-edge to them and re-welding for possible cure to slight bow?
Cut, weld, cut back, starboard, upper side-rail (had a bow, then the straight-tube that I used to re-align had a bow).
Cut welds on all side-rails (all had slight bows in them).
Grind excess metal from left-over welds.
Grind and sand weld build-ups.
Sand weld build-ups. Make jig for straightening side-rails.
Align and tack on all six upper side-rails.
Not happy with side-rails. Cut new blanks.
Tried cleaning off surface rust from blanks. TOO MUCH time... decided I'll order new material.
Waiting on material for side-rails so I decided to drill the holes for "SL wire lugs" for the upper wing center section.
Cut all eight lugs from material. Rough ground two to shape.
Ground all SL lugs to size. Filed and sanded three close to finish.
4200 hours !
Filed and sanded SL lugs. Cut six blanks for new side-rails.
Drilled 44 holes in side-rails.
Clean off paper pattern.
Glue on paper patterns.
Grind and sand edge of side-rails.
Began drilling rivet holes.
Finish drilling rivet holes.
Cut off old side-rails, begin grinding down welds. Drill out old anchor-nut rivets from side-rails.