Ripped down and screwed on a few 2x4s for the bottom of the upper wing center section jig. The base of it is 1/2 inch MDF and bows when sitting on the saw horses.
Jun 14
.5hrs
Work on the upper wing center section jig.
Jun 24
.3hrs
Glued up spar jig supports.
Jun 25
1hr
Attached spar supports which weren't 90 degrees to table - cut side supports and tried glueing/attaching... not working. Need to make substantial spar supports and attach to table. At the expense of looking like a slacker... I don't want to rush along with "okay" and not have it done right.
June 26
1.3hrs
Remade spar supports out of 1/2 inch MDF - glued up first side.
Jun 27
.1hrs
Glue up second side of spar supports.
Jul 5
3.3hrs
Work on the upper wing center section. Attached spar jig mounts and mounted and locked in both front and back spars. Needed to shave down both inner box ribs to fit.
Jul 6
.3hrs
Spent over an hour looking for pieces to the large metal brackets that apparently don't exist. Review of the plans (of which I put down as .3 hrs work time) and then looked for some of the parts for the large brackets, which I thought I made.
Jul 7
2.6hrs
Filing and sanding the fittings for the upper wing center section; the large multi-piece fittings for the spars.
Jul 8
.8hrs
More finish sanding on the cabane attach fittings for this upper wing center section
Jul 9
1.3hrs
Rough cut and ground down to size three more pieces for the fittings on the upper wing center section.
Jul 11
1.4hrs
Rough cut and ground down three more pieces for the upper wing center section fittings.
Jul 13
1.5hrs
Rough cut and and ground down the last two complex parts for the upper wing center section fittings. Filed down the edges on all eight. Still need to cut out the four rectangular bottoms for the fittings.
Jul 16
1.7hrs
Sanded edges of four of the fitting pieces to 220 grit. Still four to do.
Jul 17
1hr
Finished sanding, to 220 grit, the final four parts for the upper wing center section fittings.
Jul 18
1.4hrs
Cut out, ground down and sanded to 220 grit, the bottom four pieces of these fittings.
Jul 21
1hr
Glued up 2x4s and plywood to make spar jig for fittings.
Jul 23
1.8hrs
Tried ripping down glued up wood. Not happy with results. Went out and purchased better pine and glued up for second attempt at making jig for fittings. I also notched the two metal ribs that go at the top of the main landing gear. They're ready for welding up.
Jul 28
1.1hrs
Glue 1/16 inch ply to glued up faux spar to give correct hieght. Filed and sanded remaining two pieces of upper wing center section fittings.
Jul 29
1.3hrs
Aligned and tacked/partial weld of two metal ribs at the top of the main landing gear.
Jul 30
.9hrs
Took the main gear off of the fuselage and welded the metal ribs on them the rest of the way.
Jul 31
1.3hrs
Did some looking over of the stand-off and former layouts I did a little while ago to make a plan for how to attach and where things go.
Aug 1
1.4hrs
Made a few jigs to hold the formers in place.
Aug 3
1.7hrs
Laying out the formers on the fuselage. Working through how best to align them.
Aug 4
2.4hrs
Made the back former jig (to hold back former in place. Fine tuned jig position. Trial run of formers on jig.
Aug 5
1.3hrs
Worked on CAD drawings for the formers. Marked out measurements so that I can make blanks.
Aug 6
3.0hrs
Drew up and cut out three former patterns out of display board.
Aug 7
3.0hrs
Same as yesterday. More drawing and cutting of patterns.
Aug 8
.7hrs
Still more drawing and cutting out of patterns.
Aug 9
1.8hrs
More patterns cut out.
Aug 10
2hrs
More patterns cut...
Aug 12
2.2hrs
Cutting out more patterns...
Aug 13
1.8hrs
Still cutting out more patterns.
Aug 14
2hrs
Finished cutting out the rest of the display board patterns.
Aug 17
1.2hrs
Started fitting up the cut-outs to the fuselage.
Aug 18
1.8hrs
More fitting up of the cut-outs. Not all the way there yet, but I think I've hit the mark with the shape !
Aug 19
2.3hrs
Cut some additional patterns and fisished taping to the fuselage. Nice job... now to start bending those formers.
Aug 21
2.5hrs
Made a new bending jig for the formers. Bent one of the existing bent formers to the new shape of upper Station 27.o. Looks GREAT!
ditto
N/A
Spent several hours today researching material for fuel tanks then measured and ordered 3003 H14 aluminum for both tanks.
Aug 22
.5hrs
Another re-bend of a former. This one only took a 1/2 hour and that included cutting down a plywood pattern to use for shaping it.
Aug 24
1hrs
Still... another re-bend of a former.
Aug 25
1.5hrs
Bent up two more formers; upper and lower for Station 46.
Aug 26
.8hrs
More formers...
Aug 27
1.2hrs
Bent up more formers.
Aug 28
1.5hrs
Bent the first of several two-part turtle deck formers.
2100 hours
Aug 30
1.3hrs
Bent another one of the 2-piece turtle deck formers
Aug 31
1.4hrs
Bent up another 2-piece turtle deck former.
Sept 1
3.8hrs
Worked on trying to figure out how to align the formers for welding, reading about the turtle deck build and made former patterns for the bottom and sides at Station 10.5.
Sept 3
5.5hrs
Four different sessions today; bent up three formers (bottom and sides for Station 10.5), took measurements on fuselage and turtle deck formers to begi tacking these on and I made a jig and tacked up the formers for the turtle deck/headrest.
Sept 6
1.6hrs
Welded up two additional two-piece formers.
Sept 8
2hrs
Reading the plans for the baffles on the Upper Wing Center Section Wing tank. Read Tony B's chapter about bending metal ribs(same as the baffles). Bought Poplar wood for baffle pattern and drew up baffle blank on wood.
Sept 9
.9hrs
Poplar is not a good wood for making pattern molds for bending up aluminum (what I thought was a hardwood... is a hardwood by cellular standards but not by hardness standards). It is actually about as hard as pine. Needed to go back out and buy a piece of oak for making my pattern. Repeat of yesterday.
Set 13
.7hrs
Cut out and sanded the 5 degree cut back on the form blank for the baffles.
Sept 14-17
N/A
Research on making metal ribs, flanging lightening holes, etc.
Sept 18
1.6hrs
Cut to size, measured location, centered then tacked two formers into place.
Sept 19
1.1hrs
Trimmed the ends off the former at station 105.o. Figured out the bracket that I'll make for attaching formers that extend past the longerons; similar to the rear landing gear attach points.
Sept 22
3.3hrs
Made the first set of brackets for the formers at station 105.o. Tacked into place then tacked on former. Later on at night made a second set (for the back-side to sandwhich the former.)
Sept23
2hrs
Drew up patterns for several more former brackets.
Sept 26
1.9hrs
Drew up an additional pattern and cut out the former brackets for Station 27.o.
Sept 30
1.4hrs
Made former brackets for Station 49.06.
Oct 1
1.6hrs
Started fitting up the former to Station 27.o. Marked, measured, trimmed.
Oct 2
2 hrs
Remade Station 27.0 brackets. Remeasured placement and location for former and brackets. I'll tack into position after checking again next session.
Oct 4
1.2hrs
Rechecked placement and location for former Station 27.0. Tack welded it into place.
Oct 6
1.5hrs
Tack welded former at Station 49.06.
Oct 7
2.5hrs
Cut brackets for side formers at Station 27.o. Fitted up and tack welded one former onto fuselage.
Oct 9
.8hrs
Figured out the plan of action for cutting the aluminum for the tanks. Confirmed and rearranged the cutting for better use of material.
Oct 12
1.4hrs
Unrolled .o40 aluminum for upper wing tank. Cut the first two baffles; an hour for the first one and .4 for the second one.
Oct 13
1.6hrs
Cut three blanks and finsihed cutting two baffles from the three.
Oct 15
.8hrs
Cutting more baffles.
Oct 16
.9hrs
Cut both end caps for fuel tank.
Oct 17
.3hrs
Cut baffle test piece (fluting, ligthening holes, etc.)
Oct 20
2.3hrs
Cleaned up edges of all aluminum baffles and end caps.
Oct 21
2.7hrs
Unhappy with size of baffles and end caps... trimmed them down a bit. Discovered that they were a little oversized when I placed the wood forming block up to them.
Oct 22
1.1hrs
Deburred and sanded edges of two baffles.
Oct 23
1.1hrs
Same as last night... did the remaining four.
Oct 24
1hr
Cut top block of forming block and drilled 1/4 inch holes for alignment. Ready to start forming baffles and end caps !
Oc 27
2.5hrs
Worked on trimming the baffles and end caps for the upper wing tank.
Oct 30
2hrs
Needed to work more on the baffles and end caps. When I went to put the relief holes in it I discovered how I needed to do it. I think they're just about ready for bending.
Oct 31
.8hrs
Filed and sanded corners that I cut out the other night.
Nov 1
1.9hrs
Bent the edges on all six tank "ribs".
Nov 5
1.5hrs
Laid out hole patterns on tank ribs.
Nov 6
1.4hrs
Did a test ligthening hold and flanged it. Turned out nice. Drilled two more holes; (2) 3 1/2" holes in one aluminum tank rib.
Nov 7
1.5hrs
More lightening holes cut into fuel tank ribs.
Nov 10
3.6hrs
Cut the additional lightening holes. Deburred and began flanging holes.
Nov
11
2.3hrs
Finished flanging holes.
Nov 12
1.2hrs
Cut out blank for new end cap for upper fuel tank then cut shape of rib.
Nov 13
1hr
ditto to last night on the second end cap...
Nov 14
1.8hrs
Drilled alignment holes and bent over sides of both end cap ribs of upper fule tank.
Nov 15
1.6hrs
Filed down sides of fuel tank end cap ribs then took the fluting tool to them to straighten them.
Nov 19
.5hrs
Looking over CAD to figure out stringer stand-offs... making a plan.
Nov 22
1.5hrs
Cutting jigs for boards that will hold boards at correct height for stringers.
Nov 23
3.9hrs
Continuation of yesterday. Fitted up both side-center stringers. SWEET !!!
Nov 24
1.8hrs
Measuring and cutting wood for stringer jigging.
Nov 25
2hrs
More of the same; measuring and cutting wood for stringer jigging. Finished jigging for sides and measurements I did in CAD pretty much were much how it will look. Needed to design stringer connects for the forward and rear connects to formers. Spent about 1/2 hour creating connects/tabs in DeltaCAD.
Nov 26
1.5hrs
Cut patterns out for the forward and rear stringer connects/tabs. Cut out of .o32 4130 and ground to size. Still a little more to do on them.
Nov 27
1.8hrs
Finished making the stringer tabs today; filed, sanded and bent over all twelve.
Nov 28
1.6hrs
Marking the correct locations on the forward most stringer attach points so that I can weld on stringer tabs. Only completed one front side.
Nov 29
.5hrs
Worked on the front stringer tabs.
Dec 1
1.4hrs
Tack welded on all six front tabs.
Dec 2
2.7hrs
Clamped on all six side stringers. Looked like waves. Nothing I did took all the wave out of them. Need to figure this out.
Dec 3
1.4hrs
Worked on trying to figure out how to level the stringers front to back. Jigs weren't working. Idea - laser level !
Dec 4
.9hrs
Used new laser level to level one of the stringers. Worked beautifully.
Dec 5
2.5hrs
Tacked on three stringer stand-offs. don't ask...
Dec 6
1.7hrs
Tacked on another stringer stand-off and leveled the second stringer.
Dec 7
3.7hrs
More work on aligning, grinding to size and tacking on the string stand-offs. Finished the second one and half-way through the third.