More work on the lower enclosure. Also glued up the jig for the side enclosures.
Cut out shape of side enclosures (jig) from the glued up oak. Sanded and rounded edges. Marked out the first aluminum blank.
Flanging the lower enclosure next to the pilot's seat.
Made one side enclosure; cut blank up to drilling lightening holes.
Flanged the lightening holes on the first side enclosure.
Made second side enclosure; cut blank up to drilling lightening holes.
Flanged the second side enclosure.
Created paper patterns for the outside bottom and side enclosures.
Cut out bottom former/jig for outer/lower enclosure out of oak.
Traced then cut out bottom enclosure from the aluminum.
Formed the lower/outer enclosure. Made jig/former for outer/side enclosures.
Traced and cut out both outer/side enclosure blanks.
Formed the port-side outer enclosure. Still need to make it more ridgid. Maybe run two beads down the center of it?
Formed the starboard-side outer enclosure. Still need to clean it up a bit and make it more ridgid.
Cleaned up the edges of the enclosures; taking off the excess aluminum overhang and smoothing out the edges.
Worked on aligning and tack welding on the tabs for the enclosures.
Aligned and tacked on the starboard side enclosure tabs. Welded on both the starboard and port side tabs that were tacked. Aligned, jigged and tacked on lower/inside enclosure tabs. Made two additional flat tabs to use in that area as well (for smaller 3/8inch tubing).
Welded on lower/inside enclosure tabs. Notched lower/inside enclosure.
Notched and re-bent the edges of the two inner/side enclosures. Needed to put an approx. 15degree beed in the sides to get them to fit properly.
Cut out first spar patterns. Need to check to make sure that they fit all openings then make a second set all cleaned up.
Fine tuning the spar pattern blanks.
Finished tweaking the spar blanks. Now to have the spars profiled.
Figured out what I wanted to do with the cap strips for the wings and cut them down on the table saw.
Looking over the fuselage writing down a punch list of things to do on it; brackets and a few other things.
Research to figure out what I need to do for the battery tray/shelf support. Found my answer.
Constructed jig for battery support. Cut and fitted tubes for battery support.
Research... reading Tony B's red book for information about battery's, firewalls and what gets mounted to a firewall.
Welded up the battery tray support frame. Leveled and tacked to fuselage. Measured, cut and tacked hanging brackets for battery tray support. Welded up complete unit (except two small welds on the bottom of one tube-intersection.
Looked over some of the stacks of notes I have on the various parts still needed to be made. Found the list of brackets that need to be made and welded to the fuselage. YES !
Checking list to see what I want to do next. Looking over fuselage to see if there are any welds that need to be finished.
A lot of researching. A little work. Made the pattern and drilled/cut/filed/sanded the mounting bracket for the rudder trim tab. Put the elevatiors back on the fuselage to start work on the servo/trim tab system.
Made one new tab horn. Aligned both on trim tabs and tack welded them onto the trim.
Lots of misc.; welded on rudder tab bracket, designed, made and welded on the two brake tabs and designed and rough cut the two brackets for the front springs for the rudder pedals.
Worked on: finalizing and welding on the rudder spring brackets, re-attached the trim tabs, confirmed tube list for trim/servo system, measured tubing of existing UC-78 engine mount and made list for ordering tubing.
Researching engine mount. Making calls. Searching the internet. Spent hours doing this. Ordered tubing for engine mount and trim/servo system.
Worked on reaming tubing and cutting tubing for trim/servo system.
More work on the trim/servo system. Filed/sanded the 3/8inch tube that fits into the tabs. Measured, cut and lathed four bushings to size. Welded on trim horn to center bushing.
Leveled the horizontal stabs (welding the forward or rear attached... I must have warped the tubing so that it would have a pretty good drop off - 1inch at the tip of the port stab). Heated tubing to bring it close to level. Will use stab wires to make perfect. Cut and lathed down two additional bushings (5/8inch) for trim/servo system. Spent time trying to figure out how to un-do my ratcheted straps which I WAS going to use on straightening the stabs - didn't so I took .3hrs off time.
3000 hours !!! - not sure if I should be happy or sad about that ???
Re-heated horizontal stab tubes again - leveling up stabs. Worked on the bushings for the trim/servo system. Cleaning/deburring bushings. Sanding down tubes for fit, etc etc etc. Still working on it.
Sanded tubes in servo/trim system to allow bushings to slide into position.
Still working on getting the bushings to slide/turn on the trim/servo shaft easily. Still needs just a little bit more work.
More work on the trim/servo system. Close to welding on the bushings. Close... Also leveled the horzontal stabs length-wise and width-wise. Marked ply with tab horn and servo tab so that I can figure out the connecting rod.
Figuring out the bend angle for the tab link shaft for the trim/servo system.
Aligned system. Tack welded bushing in place. Could get off all except one bushing from shaft. That broke out. Couldn't get off shaft. Re-made. When drilling out servo I enlarged the hole. Need to remake entire system now.
Re-thinking the instrument panel.
More re-thinking of the instrument panel.
Cut new trim horn from .o71 4130. Drilled all holes. Ground to size. Filed and sanded edges.
Cut and reamed new 1/2inch tube for trim horn. Match drilled trim horn tube with trim/servo shafts. Welded trim horn onto 1/2inch tube. Re-aligned horizontal stabs. Test fit all on horizontal stabs.
Checked level of stabs and fuselage; within 2/10ths of a degree. Aligned trim/servo system in stabs. Tacked in last bushing. Took apart and finish welded bushings then reamed. Made jig for bending tab link arm.
Finished up the trim/servo system. Positioned and welded on the servo horns. Cut, notched and welded up the tab link arms.
Started putting the upper wing tank together. Match drilled upper/front side to baffles. Clecoed together.
Re-work of the top-side of tank skin to ribs (attached them on backwards the first time).