Match-drilled stringer plates to tail cone and installed/glued on nut plates.
Locked on the nut plates using #2x1/4inch brass screws and epoxy. Reamed the trim handle bracket and three brackets for the rudder.
Aligning the stringers on the tail cone. Marking for cutting. Quadruple checking.
Realigned rear points of turtledeck stringers on the tail cone. Measured, marked and made a simple jig to hold stringers in place. Glued stringers into position. Checked firewall blank to first upper former for smooth transition. Thinking through firewall, thurtledeck door and other systems.
Finishing touches on the tail cone. Tweaked the fit of the four remaining turtledeck stringer stand-offs and glued in place.
Made the floor for the battery tray.
June 23 - 24
BIG storm - no power
Made the end-tips for the turtledeck stringers.
Figured out and made the mounting plate for the rear throttle quadrant.
Designed and made the bracket for the front throttle quadrant.
Re-made the front quad bracket.
Not happy with the look of the front quad bracket. Decided to make something that would look the same as the back attachment. Measured, cut and fitted the support tube for the front throttle quadrant. acked then partially welded it in.
Not happy with the way the top part of this tube was welded in. Ground it off today. Will replace with new piece tomorrow.
A lot done today; finished grinding, filing, sanding off first weld marks, cut and welded on new support tube, and made the mounting bracket for the front throttle quadrant start to finish.
Cut the tacks and re-mounted both throttle quad mounts.
Making a "practice piece" for the turtledeck door frame. Will make the new and improved one tomorrow.
CADing up notch pattern for turtledeck door.
Work on the new and improved turtledeck door frame. Drilled alllll those holes and started notching it.
Cleaned and sanded the back side of the battery tray. Didn't log the hours for looking for a new v-belt for the metal bandsaw.
Finished up the tail-end of the turtledeck stringers then started working on the the design of the seat backs. Made the pattern for the pilot's seat.
Notched the curved part of the turtledeck deck's door frame/support. Drilled the rivet holes in the straight lower section of th L-shapped aluminum for the lower portion of the door. Cut out the first blank for routing the skin of the door.
Cut new door blank from 1/4inch ply instead of 3/4inch MDF. Much easier to get the correct fit. Cut an over sized blank based on this ply pattern then cut closer to size and started filing and sanding. Still needs to be filed a bit more to fit.
Drilled and clecoed the top radius on the turtledeck door-to-frame radius.
Work on the firewall: cut the sheet to size and worked on the design in CAD. Got it figured out.
Drew the 44" diameter circle then marked out where the bead lines will go and the exhaust ramp.
Cut the firewall shape out of the stainless steel.
Glued the notch pattern on the aluminum flange for the firewall and drilled the deburred 252 holes.
Rough cut the notches for the first 8ft aluminum "L" for the firewall flange. Need to file and sand it before moving onto the next piece.
Filed all 126 notches; both sides. Still need to hit them with a fine sandpaper.
Filed edges of notches and started sanding them.
Drilled rivet holes on second firewall flange; used center bit to start hole and finished with a #40 bit.
Finished rivet holes on second firewall flange. Still needed to deburr.
Drilled 126 stress relief holes on the second firewall flange.
Notched and filed smooth... the second firewall flange L-shaped piece. Looked and found the rivets Gus gave me back in... 2007. No need to buy any of those 3/32nd rivets.
All 252 notches have been sanded with 220 grit. Need to pass 400 grit over them and then they're ready for riveting. and... Sanded the tips of the turtledeck stringers.
400 grit sanding of the firewall flanges. Also tried deburring the edges of the slotting but it wasn't working. Will be ordering the correct tools tomorrow.
Spent about 3 hours "working" on the biplane tonight. Most of it looking for stuff or reading up on the seats. The hour... CAD drawing of the seat backs.
Cutting out tabs for attaching sheet metal skins. Gotta do something when I'm waiting on that riveting stuff.
On my way back from flying I stopped at Fazzio's to pick up a 4ft x 10ft sheet of .o32, 5052 aluminum. It's for the seat pans and seat backs.
Spent all night trying to find information on how to use a rivet squeezer. No luck. Emailed Tatco in the end.
Deburred the flanges for the turtledeck hatch and both 8ft flanges for the firewall.
More flange sanding and the start of learning to learn rivet squeezing.
Cut the blanks out for the pilot's seat pan and back.
Filed and sanded sides of seat back blanks. Cut the center out of the frame.
Drilled the rivet holes and bent the edges of one seat back insert.
Re-drew seat back insert. Wasn't happy with the one I made... made some changes to it.
Worked on the turtledeck hatch. Sanding down the sides to make it fit. Discovered that I have the plate flipped instead of flopped. DAMN !
Traced turtledeck hatch pattern on a new piece of aluminum. Rough cut to size then filed filed filed for a nice snug fit.
Final file of aluminum hatch to fit opening. Drilled and clecoed top of hatch for 3/32nd rivets.
Cut outer hatch cover blank. Match drilled inner hatch cover with outer hatch cover.
Finally tweaking of fit of hatch to opening. Notched the flange for possible way of attaching... also allows me to get the rivet tool to the rivets.
Started riveting the hatche's front, back and the flanges together.
Actually spent 3.5hrs on the build tonight; 2 hrs riveting and 1.5hrs re-fiting the hatch in the turtledeck opening.
Another test fit of the hatch in the turtledeck baggage opening... still fits! Cut the blank for the new seat back insert. Glued on the pattern and cut to shape.
Seat back insert; filed/sanded edges smooth, drilled rivet holes, bent over edges. It's ready for attaching to ourter frame.
Filed and sanded outer seat frame. Tweaked seat insert... and THEY FIT!
Opened up the seat frame a little bit more for easier fit. Match-drilled insert to frame then deburred.
Spent about .5hrs taking tape and glued on pattern from seat parts.
More deburring of seat insert and frame.
Spent 1.9hrs tweaking/cleaning/more deburring of seat frame and insert. Didn't log the 3+ hours of cutting over 100 rivets to length.
Started squeezing rivets; top, bottom and one side completed. Several of them need to be re-done.
Drilled out seven of the ten bad rivets. Screwed up the other three. Made this first seat back into a test piece.
Cut out blank for new seat back insert. Glued on pattern and cut to shape.
Filed sides to lines... drilled and deburred all holes.
Bent the sides of the re-make of the seat back insert. Cut out the re-make of the seat back frame.
Final filing of seat back frame (inside edges) then match-drilled and deburred holes.
Spent 1.3hrs cutting down rivets for seat back.
Made both heel rails for the pilot's seat. Still need to drill and attach L-shaped flanges.