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.
Work on the upper wing center section jig.
Glued up spar jig supports.
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.
Remade spar supports out of 1/2 inch MDF - glued up first side.
Glue up second side of spar supports.
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.
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.
Filing and sanding the fittings for the upper wing center section; the large multi-piece fittings for the spars.
More finish sanding on the cabane attach fittings for this upper wing center section
Rough cut and ground down to size three more pieces for the fittings on the upper wing center section.
Rough cut and ground down three more pieces for the upper wing center section fittings.
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.
Sanded edges of four of the fitting pieces to 220 grit. Still four to do.
Finished sanding, to 220 grit, the final four parts for the upper wing center section fittings.
Cut out, ground down and sanded to 220 grit, the bottom four pieces of these fittings.
Glued up 2x4s and plywood to make spar jig for fittings.
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.
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.
Aligned and tacked/partial weld of two metal ribs at the top of the main landing gear.
Took the main gear off of the fuselage and welded the metal ribs on them the rest of the way.
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.
Made a few jigs to hold the formers in place.
Laying out the formers on the fuselage. Working through how best to align them.
Made the back former jig (to hold back former in place. Fine tuned jig position. Trial run of formers on jig.
Worked on CAD drawings for the formers. Marked out measurements so that I can make blanks.
Drew up and cut out three former patterns out of display board.
Same as yesterday. More drawing and cutting of patterns.
Still more drawing and cutting out of patterns.
More patterns cut out.
More patterns cut...
Cutting out more patterns...
Still cutting out more patterns.
Finished cutting out the rest of the display board patterns.
Started fitting up the cut-outs to the fuselage.
More fitting up of the cut-outs. Not all the way there yet, but I think I've hit the mark with the shape !
Cut some additional patterns and fisished taping to the fuselage. Nice job... now to start bending those formers.
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!
Spent several hours today researching material for fuel tanks then measured and ordered 3003 H14 aluminum for both tanks.
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.
Still... another re-bend of a former.
Bent up two more formers; upper and lower for Station 46.
Bent up more formers.
Bent the first of several two-part turtle deck formers.
Bent another one of the 2-piece turtle deck formers
Bent up another 2-piece turtle deck former.
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.
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.
Welded up two additional two-piece formers.
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.
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.
Cut out and sanded the 5 degree cut back on the form blank for the baffles.
Research on making metal ribs, flanging lightening holes, etc.
Cut to size, measured location, centered then tacked two formers into place.
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.
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.)
Drew up patterns for several more former brackets.
Drew up an additional pattern and cut out the former brackets for Station 27.o.
Made former brackets for Station 49.06.
Started fitting up the former to Station 27.o. Marked, measured, trimmed.
Remade Station 27.0 brackets. Remeasured placement and location for former and brackets. I'll tack into position after checking again next session.
Rechecked placement and location for former Station 27.0. Tack welded it into place.
Tack welded former at Station 49.06.
Cut brackets for side formers at Station 27.o. Fitted up and tack welded one former onto fuselage.
Figured out the plan of action for cutting the aluminum for the tanks. Confirmed and rearranged the cutting for better use of material.
Unrolled .o40 aluminum for upper wing tank. Cut the first two baffles; an hour for the first one and .4 for the second one.
Cut three blanks and finsihed cutting two baffles from the three.
Cutting more baffles.
Cut both end caps for fuel tank.
Cut baffle test piece (fluting, ligthening holes, etc.)
Cleaned up edges of all aluminum baffles and end caps.
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.
Deburred and sanded edges of two baffles.
Same as last night... did the remaining four.
Cut top block of forming block and drilled 1/4 inch holes for alignment. Ready to start forming baffles and end caps !
Worked on trimming the baffles and end caps for the upper wing tank.
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.
Filed and sanded corners that I cut out the other night.
Bent the edges on all six tank "ribs".
Laid out hole patterns on tank ribs.
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.
More lightening holes cut into fuel tank ribs.
Cut the additional lightening holes. Deburred and began flanging holes.
Finished flanging holes.
Cut out blank for new end cap for upper fuel tank then cut shape of rib.
ditto to last night on the second end cap...
Drilled alignment holes and bent over sides of both end cap ribs of upper fule tank.
Filed down sides of fuel tank end cap ribs then took the fluting tool to them to straighten them.
Looking over CAD to figure out stringer stand-offs... making a plan.
Cutting jigs for boards that will hold boards at correct height for stringers.
Continuation of yesterday. Fitted up both side-center stringers. SWEET !!!
Measuring and cutting wood for stringer jigging.
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.
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.
Finished making the stringer tabs today; filed, sanded and bent over all twelve.
Marking the correct locations on the forward most stringer attach points so that I can weld on stringer tabs. Only completed one front side.
Worked on the front stringer tabs.
Tack welded on all six front tabs.
Clamped on all six side stringers. Looked like waves. Nothing I did took all the wave out of them. Need to figure this out.
Worked on trying to figure out how to level the stringers front to back. Jigs weren't working. Idea - laser level !
Used new laser level to level one of the stringers. Worked beautifully.
Tacked on three stringer stand-offs. don't ask...
Tacked on another stringer stand-off and leveled the second stringer.
More work on aligning, grinding to size and tacking on the string stand-offs. Finished the second one and half-way through the third.