Welded up the harness support and tacked it into place.
Welded on the main support to the fuselage. Notched and fitted the first of two forward, angled support tubes for the shoulder harness support.
Notched the second angled support tube. Took me longer the second time around and I had a pattern for the one end of it ?
Welded on the front, angled tubes for the shoulder harness support.
Spent way more time on this than two hours. Looking through the micofilm for the motor mount nacelle fitting drawing. Found it !
CADing motor mounts
Cutting first part of motor mount. Also... started thinking about re-CADing; thinks may not be as they appear to be...
Re-drawing motor mount parts.
Glued on and rough-cut the first motor mount part again.
Second and third pieces of the first motor mount fitting cut and filed to size.
Drill holes in three pieces of first motor mount fitting. Weld on battery tray (pain in the arse).
Draw up and rough cut four harness webbing guides.
Looking at fuselage. Figuring things out.
Thinking hard about the how to make the brackets for the throttle controls; on line and reading Tony's books.
Rough-cut two of the three pieces for the second of four motor mounts.
Rough-cut two more. Same pieces but for another motor mount fitting.
Rough-cut two more parts for the motor mount. Ground down to size all the parts cut so far.
Rough-cut and drilled the remaining three parts and then ground them all to shape.
Filing sides of all the parts cut so far for the motor mounts.
Jun 7 - 9
Re-thinking all this bending of the motor mounts
Checking and re-checking the calculations of bend allowance and set-backs.
Started bending the fittings. Cut the 2x4's for the crate of which I'm not counting as time.
Spent all day getting the Jake crated up.
Began making bends on motor mount fittings.
Re-made one of the center pieces of one of the fittings. Filed and then bent first bend.
Bend second arm on all four motor mount center pieces. Needed to re-make two of them.
Trip to the airport to load out the radial for the trip back to my place.
Cut off lips of motor mount side pieces. Made match-sets of all four. Needed to tweak bends on the side pieces to make true 90 degree bends.
Made all four bends on the outer two pieces of the first motor mount fitting. Rough-cut the angles on them too.
Repeat of yesterday on the second motor mount. Learned a lot and it's paid off.
Repeat of the past two days. Although, I made two in half the time.
Went down to bend the 45's on the center section of the motor mount and discovered I needed to grind down the wings so that they could bend past the bottom section. Spent the time trying to file them down. There's got to be an easier way.
Used a hand-held grind to grind down the wings. Bent then rough cut two of the center section pieces of the motor mount.
Bent and ground to rough shape two sets of side pieces.
Ground all 12 pieces down close to shape. Filed and sanded to lines.
Drew up motor mount fitting base plate on CAD.
Need to modify patten before cutting out bottom plates for motor mount fittings. Decided to look to see what needs to still be done on the fuselage; Process of putting items made onto fuselage to see what still needs to be done. Lots !
Cut out, ground and filed to size, and bent wings on two of the four motor mount bottom plates.
Made the two additional motor mount bottom plates.
Burned off the patterns from the motor mount pieces. Ground off the tack welds from station 0.o (the whole sway wire dealio).
Squared the motor mount pieces up and then welded the outside of four of the outside pieces.
Welded up the remaining pieces; four outside and four inside.
Welded the center sections to the two outer sections on all four fittings. Only welded the curved part on each.
Final four welds on two of the motor mount fittings.
Welded up the two additional motor mount fittings.
Re-weld on two of the weld lines on the motor mounts. Tacked the other two fittings onto their mounting plates. Looked at (again) and decided to move forward with doing the fabric on the seats and rear fuselage dividing panels in a "Military" looking canvas.
Finish welds on the first of four motor mount fittings.
3800 hours !
Finsihed the welding on two more motor mounts.
Welded up the last motor mount fitting.
Finishing touches on the motor mounts then position and tacked them into place !
Made blank pattern of firewall for locating motor mount fitting openings before cutting actual holes in the firewall.
Figured out and made the patterns for the openings in the firewall.
Measure, mark and cut openings in corrugated plastic firewall blank. Measured and aligned on firewall. Taped motor mount opening patterns in place.
Cut 2x4 straight-edge at 20degree angle. Additional testing. Good results.
Drilled all 12 holes in the firewall.
Cut all four openings in the firewall. Still need to have their edges cleaned up.
Cleaned up one of the openings in the firewall.
Cleaned flashing from the other three openings in the firewall. Test fit to fuselage... centers nicely.
Made six bushings to secure the firewall to the fuselage. Still need to cut a few washers to weld to the ends then weld them to the fuselage.
Cut out and filed/sanded six .o50 thick washers for the firewall mounts. Made a simple jig for welding the bushing and the washers together.
Welded the washers and bushings together to make the firewall mounts.
Aligned and tacked on firewall mounts.
Cut-off and re-aligned one firewall mount. Re-tacked another. Trial fit of firewall again. Designed and cut pattern for aluminum seat back corner cover.
A night of re-doing things; re-checking, re-tacking, re-reaming...
Re-jigging the firewall for proper location. Testing; drilling into the stainless steel seeing if what I thought would work would work. Don't use a wood backing block.
Designed a different way to clamp the wood in place for the height of the firewall. Got all things aligned for the final time? Well see tomorrow...
Checked the firewall alignment again... then drilled four of the six holes. The firewall is in place.
Final two bolt holes in the firewall. Taped display board in place to see what it would look like with sheet metal in place.
re-Made an upper former that's located just behind the front seat.
re-Made the upper former. Again.
Fit and tack new former.
Adjust upper former at pilot's cockpit. Cut too short and had to used an extra one I had for that area to align, cut and tack.
Actually a lot more time than an hour. Figuring out the tabs and strips I want to use for attaching the sheet metal skins.
Same as yesterday. Figuring out the tabs and strips. A lot more time than an hour spent on it.
Drilling and deburring 33 holes in 33 former tabs.
Cutting out and grinding to shape 33 former tabs.
Bent and trimmed former tabs.
Filing and sanding the sides of the tabs. Half-way done.
Grinding and sanding former tabs to size. Spent time figuring out how I need to jig and space them for welding.
Finished former tabs (grinding to length). Spent time figuring out the finishing of the gap just below the turtledeck in the pilot's cockpit area.
Working on the trim for gap just below the front turtledeck as mentioned above.
Change of plans on that piece for filling the gap in front of the turtledeck. Using the smaller "L" extrusion. It's now notched. Fits great. Need to now cut and bend mounting tabs on the top.
Drilled, notched and filed smooth... the L-shaped extrusion for the gap between the turtledeck and the tube in front of it.
The tinnerman nuts are the wrong size. Need to send back and exchange. So... need to fill time. Decided to make the side formers for the sheet metal. Hand-cut the starboard .o25 sheet metal blank, then drilled holes for the anchor nut plate openings and then match-drilled the rivet holes for the anchor nuts.
Cut the port .o25 sheet metal blank on the bandsaw (saw that I could make it smaller and could do it on the bandsaw) then drilled the holes for the anchor nut openings.
Match-drilled holes for rivets in port side former. Banged the starboard former's bottom bend.
First banged former looked great so I decided to do the second one.
Test dimples then dimpling both side formers.
Filed down rivets. Failed attemps at riveting in the close quarters of the bend. Will need to modify one of the squeezer heads.
Rivet anchor nut plates onto both side formers. Happy with the second one... not the first one. Bend is too close to where I need to rivet for the first one.
Cut .o25 steel sheet to re-make first one.
Bent then drilled holes in re-make of first side former.
Squeezed rivets in above side former.
Cut re-make of second side former then drilled holes. Ready for riveting.
Match-drilled rivet holes. Bend edge. Dimpled rivet holes. Ready for rivets.
Riveted the anchor nut plate onto the second forward side former. Cut the blank for the center, starboard side former.
First middle, starboard side former; drilled, match-drilled, then dimpled. Ready for rivets.
Worked the one center side-former; drilled screw holes, match-drilled rivet holes, put bend on edge then dimpled.
Drilled out rivets then re-riveted piece I drilled rivets out of.
Working on jig pattern for holding sheet metal tabs in place. Glued down pattern and drilled holes.