Put the stringers back on the turtledeck for another test fit. It's close... need to trim a few stand-offs and glue on a spacer.
Glued on top four turtledeck stringers.
Glued on bottom four turtledeck stringers and then glued the tips of the double-stringers.
Glued down the bottom stringer of the double-stringers.
Glued on top stringer on double-stringer.
Started gluing on the second layer of turtledeck stringers to build them up to 5/8inc.
Same as yesterday... just different stringers.
Glued on the bottom stringer of the two double-stringers.
Glued on the upper stringer of the two double-stringers.
Glued on first layer stringer for spline on turtledeck. Also... glued the tips of both double-stringers together.
Glued second layer of stringer on spline. Glued tips of double-stringers a little bit further in.
Slow going... filed the lower, starboard side, bulkhead board so that the transition ply will fit within the turtledeck design and not overhang the fuselage. Trimmed and fitted a poster board test piece; figuring out the exact look still.
More work on the turtledeck ply transition. I think I got it !
Cut and fitted the four pieces of ply for the ply transition on the turtledeck.
Tweaking the fit of the transition ply. Cut the scallops in two of the four pieces of transition ply.
Scallops on the second set of transition plys.
Re-made the lower starboard side transition ply.
Fine tuning the fit of the lower tranistion plys. Used the T-88 epoxy to seal the area underneath the transition ply.
Cut, fitted, sanded the two glue blocks for the lower transition plys.
Glued on the lower transition plys. Also continued using the glue to seal the ply baggage compartment.
Sanded down all the squeeze out on the surface of the plywood baggage compartment.
Sealed the backside of the two upper ply transitions then glued on the port side. Continued using the T-88 for sealing up the wood.
More sealing up of the ply with T-88. Can only use a small squeegee to get access between the stringers.
Trimmed the upper ply trans so that it was centered on the spline. Glued and trimmed to size the port upper ply trans then used the rest of the mixed T-88 to seal more of the turtledeck.
Started to sanded/blended the points of the scallops, on the ply transition, to the stringers. Needed to go back to a few areas an build the gap up a little. Placed all the stringers into position for a looksee.
Modifying the saddle gussets.
Figuring out why the lines aren't right on the turtledeck. UGH !
Measured, cut and fitted paper template for the upper wing fuel tank skin.
Rolled out and marked the aluminum sheet for cutting the sking of the upper wing fuel tank.
First cut of the aluminum sheet for the upper wing fuel tank. Yeah... when you're nipping the material away it takes a lot longer.
Another length of aluminum cut.
Final length of aluminum cut for the upper wing fuel tank.
Cleaning up the cut lines on the upper wing fuel tank skins. Re-marked and cut one edge tonight. Still have another two to go.
Marked and trimmed 2nd edge on one of two fuel tank skins. Discovered that there wasn't enough room to re-cut third edge so I kept it as is
Started marking up the skins for the upper wing fuel tank. Marked the bend lines, beading lines and rivet locations. Still need to mark the holes for the fuel lines, vent line, drains and fuel cap.
More markings on fuel tank skins. Need to trim ends so that I can do an overlap weld. I'll cut back each side 1/4inch so that I can leave the end ribs out 1/4inch for the weld.
Taking inventory of what needs to be done. Also marked the end ribs for the overlap welds and trimmed the 1/4inch off the ends of the two fuel tank skins.
Started searching for riveting information. I don't have any books on it and there isn't much in Tony B's books. I'll have to look on line. Filed and sanded the edges of the fuel tank skins.
Measured, marked and glued up the stringers for the re-do on the turtledeck (I wasn't happy with how the stringers came off the baggage area back to the tailcone.
Cleaned up the stringers that I glued up last night. Looked at the turtledeck to determine how I was going to do the re-do of the stringers.
Cut off and notched the first of many stringers on the turtledeck.
Second turtledeck stringer cut and notched. Ready for gluing.
Third one done! (getting quicker at it)
Four turtledeck stringers re-done !
Bottom stringer on the port side of the turtledeck cut, notched and ready for gluing.
Second stringer on the port side of the turtledeck cut, notched and ready for gluing.
Third stringer on the port side of the turtledeck cut, notched and ready for gluing.
Did something... don't remember now.
Last stringer on the port side of the turtledeck cut, notched and ready for gluing.
Glued on first two turtledeck replacement stringers.
One more set of turtledeck stringer re-do's glued on.
Another set of turtledeck stringer re-do's done. One more set to go.
Trimmed stringers so that I could begin figuring out attach points (they were too long and hitting the vertical tail).
More fitting... sanding shape of stringer at glue juncture. Overall, just tweaking the look and figuring out where to connect to fuselage.
Shaping and sanding the stringers. Decided that the lower two re-do's don't work (look right). I'll be re-doing those four again.
Ordered additional cap strips for the four turtledeck, re-do stringers.
Made jig to cut the holes in the tubes that will support/adjust the leading edge on the horizontal stabs.
Notched the four holes in the two tube that will support the front spar of the horizontal stab.
Figuring out the horz stab connections
More figuring of the horz stab connections. Read the section in the Skybolt manual that talks about the length of the .375x.o65 tubing. It suggest welding on tringular sections of tubing and then drilling and welding on the lower bushing into the tubing instead of the plans suggestion of welding onto the longeron/cross tube. Reamed the two lengths of .375x.065 tubing to 1/4inch.
Cut the two triangular parts to support the lower bushing that will allow the front spar on the horz stab to be adjustable. Cut this out of .75x1x.o49 rectangular 4130. Notched the ends to allow them to fit up with cross tubes and longerons.
Tacked and started welding on the triangular gussets that beef up the area for the front spar of the horizontal stab adustment/attachment.
Cleaned off fuselage, flipped and welded bottom side of trianle gussets.
Getting fuselage ready for flipping. Clearing out space on sides of tail so that I can fit the horizontal stabs on.
More of the same...
Worked on the project... ain't putting down the time. Looking for the plans sheet for the horz stab attachments. Finally found it then horsed around with placement of the stabs. So... I worked on it, but not putting down the hours worth of "fooling" around with it.
Figuring out the location of the horz stab attach points.
Figured it out... see above post.
Confirmed location of rear horz attach. Ground the bottom of the vertical tubes to allow horz tube to sit tangent to the fuselage. Confirmed square by measuring the outside points of taped in tube to the firewall (equidistance). Tack and weld tomorrow.
Reading up on the front attach for the horz stab. Put in over an hour...
Researching front attach for horz stab.
Decided on how to do the front attach for the horz stab. Re-cut the 3/4inch tube and cut the 7/8inch tube.
Aligned and rosette welded the 7/8inch tube to the 3/4inch tube. Ready to mount.
Straighten the sleeved tube by reheating. Set up the drill press to drill both 3/8inch holes.
Aligned the starboard horz stab to find the location of rear attach point. Spot welded the vertical tubes of this attached.
Aligned and tacked on rear horz stab attachment. Repeat !
More alignment of horz stab attachment. Got it to the point where I could tack and finish weld the piece.
Measure, cut and fit of port horizontal stab.
Did what I did yesterday to the starboard stabilizer.
Study plans, ask questions. Got answers.
Aligned, tacked and welded in both vertical tubes in the horz stab front attachment tube.
Reamed vertical tubes to 1/4inch.
Drilled holes in elevator horns to the correct 7/8inch, not the 3/4inch that I had.
Put in a little over an hour looking for a piece of aluminum big enough to make the spacer for the elevator horns then made the pattern. Ain't putting down the .5hrs looking for the aluminum.
Set stabs in position, mark then cut down front stab spar tubes.
Set stabs in position, mark then cut down both elevator tubes. Look GREAT !
Marked and cut the horz stab's front spar to fit up with the front attach tube.
Leveling and squaring up the fuselage and stabs for locating the position of the front attachment.
Confirming - squaring up of stabs.
First hole in stab front spar (port side).
Second hole in stab front spar (starboard side).
Found the top-centers on the back horizontal stab spar. Marked them and then put the starting holes with a centering bit.
Drill both holes in horz stab rear spars and then ream to 3/16inch.
Measured and cut insert tube for elevator spar. Removed port horz stab and drilled rosette hole for welding in insert tube. Replaced stab back on fuselage.
Rosette weld elevator front spar to sleeved tube.
Marked and ground out the area that I will position and weld in the lower bushing tube for the horz stab front attachment.
Spent 2hours, but some of that was running around looking for and figuring out stuff. Came up with a way to keep both tubes for the front attachment aligned. They each have different ID's. Took a small 4130 rod to the lather and cut the OD down to two different sizes.
Aligned the first of two vertical bushing for the horz stab attach. Measured and marked the placement of the bushings on the horz stabs for the flying wire attachments.
Welded on and reamed out both vertical bushings for the horz stab front attachment.
Drilled all four holes in the horizontal stabilizers for the flying wire attachment bushings.
Cut and fitted vertical tail brace. Drilled 5/8inch hole through metal for fitting too.
Welded in vertical tail brace.
Cut and fitted square tubing to hold forward bushing in place for horz stab upper flying wire. Welded into place.
Re-weld on last night's business. Also aligned and drilled hole for the upper, rear flying wire. Welded 1.25inch bushing into place.
Cut and squared up 4th horz stab busing on lathe.
Welded on all four bushings to horz stabs.
Reamed out all four bushing on elevators. Match drilled elevator horn spacer to both elevator horns.
Discovery. The radius on the ears of the elevator horns aren't tight enough. Unable to make fix. Will need to remake both elevator horns.
Glued on patterns and rough cut and ground to shape both elevator horns.
Filed both shapes to size and cut the 1/4inch and 7/8inch hole in one horn. Still haven't bent it to shape.
More work on the two, new elevator horns. Got the first two holes in each drilled and the ears bent.
Worked on it 3.8, but the unibit wasn't doing it's thing too well. Wasn't happy with the two horns I made yesterday so I started over again today. They're rough-cut, then drilled and now filed to size.