Heated the cross tubes/vertical tubes slightly so they wouldn't be pushing on the axles. Tacked the verticals to the axles. Notched streamlined tubes to fit better.
Tweaked the streamline tubes to fit better. Welded streamlined tubes to cross tubes. (need more O2)
Tacked streamline tubes to axles. Welded up 3/4 of one weld.
Continued welding the first axle of the right gear.
Test fit the right gear. Needed to make a slight adjustment with heating the front fitting. Started welding up second gear.
Welded up the insided angle joint of the cross tube and streamline tube on both gear legs.
Tweaked the axle on the left main gear. Came close to completely welding the back tube/fitting to the front tube. Two small welds to go.
Started welding up the second back tube/fitting to front tubes.
Finished what I started yesterday. Man, did THAT need A LOT of heat!
Check both axles for movement. Ground off, and down, the overhanging axle so that I can weld on the strap.
Ground off the back of the other axle. Ground it down so that I can weld on the strap too.
Tacked and welded on the first strap; the strap for one of the axles.
Tacked and welded on the second strap (same one as I did on Feb 26.) on the other axle. Also needed to finish welding on the back tube to the axle.
Worked on the left gear cross-tube. Used the grinder to get a better shape on the end then heated and tacked on the strap. Welded up approx. 1/2 the strap. Needs to cool before grinding away some excess.
Ground down strap on cross/streamline tube. Finished welding up. Heated and tacked strap on second cross/streamline tube. Started welding it up.
Grind and weld the second cross/sreamline tube strap.
Heated and tacked on the two remaining straps; the ones on front bushings.
Welded the strap on the first of two front bushings/attachments.
Welded most of the 2nd strap to the 2nd bushing/attachment area. Overhang a little more than I liked on the one side so I ground it down. Making a filler piece to weld to that area of strap.
Fitted and welded on that "splice" to the final strap. Reamed both front bushings of slag and then attached to the fuselage and dropped lines to check for movement. Each moved in slightly; about 1/8" each. Movement in... not bad. YES !!!
Cleaned axle near weld so that I could slip on brake backing plates. Tapped on the plates. Looked at Cleveland brakes for quite awhile... deciding on how to mount them. Need to weld on plates tomorrow.
Welded on the brake backing plates. The main gear is FINISHED !!!
Worked on getting the wheels and brakes up to speed so that I can put them on the axles. Probably spent 5 hours on this... which I ain't adding to the "build" of the biplane.
Spent several hours working on getting the wheels/tires on the gear. About 9PM I rolled it out of the garage.
Back to reading; stringer stand-offs and the wings are next.
Pulled plans to see where reversers, idler arm and control column are located. Test fitted in fuselage. Still need to weld in fuselage. Pulled out one of Tony B's books and read up on stringer stand-offs.
Started welding in the tubes for the first reversers. Spent the rest of the night cutting cardboard to start giving the fuselage a shape.
Exact placement and tacking in of of 2nd reverser and idler arm.
Spent about 1.5 hours looking at the fuselage, looking at some TravelAir Mystery Ship photos and line drawings. Thinking of how I'm going to shape it.
Cut rudder pedal axles for both front and back pedals. Looked a fuselage to see what I still needed to make/buy for outfitting fuselage.
Spent several hours figuring out and looking for the bearings for the pushrods to tail.
Worked with the CAD program to start shaping the fuselage so that I can start making the formers.
CAD work. I've got the shape and I'm ready to make formers.
Spent time reading up on, looking at and figuring out formers and stringers.
Figuring out how many and where the formers need to go, length of material, how many stringer stand offs and where they need to go. Ordered material for formers and stand offs.
Set up the shop table to do tube bending. Formed up the first upper former.
Figuring out how to build up the formers and where I can place them, given the location of other items that need to be put in and taken out of the fuselage; the fuel tank, etc.
Solved the mystery of how to attach the forward formers (the oversized ones) and made the jig for the leading edge of the tail and then formed it.
Bent 2nd former for forward fuselage... illiteration, eh?
During lunch today I did some CAD work; redesign of stand-offs (made them scalable up to 7" long for the wider fuselage). Printed off about 40 of them.
Formed the first bottom former for Station 26.o. Rough cut four stringer stand-offs.
.8 hours bending up another former, 1 hour cutting out, filing and sanding, with 150 grit, four more stand-offs. Still need to sand with 400 grit.
Looked over former/stand-off layout. Determined how far back to come with the sheet metal and where formers and stand-offs will go.
Figuring out lengths of stand-offs with the CAD.
Cut the patterns for the 3 inch stand-offs. Glued the patterns to the 4130 .o32 sheet blanks, rough cut then ground down and filed to size. Took 150 sandpaper to them.
Two work sessions today totaling 3.4 hours. Cut, ground, filed and sanded all ten 2 inch stand-offs. Tonight I spent an hour putting the bend in all the ones that had been sanded.
Remade (2) 5 inch and (2) 6 inch stand-offs; from blank to making the bend.
Made four more stand-offs; (2) 5 inch and (2) six inch.
Made (8) additional stand-offs. All were 4 inch long.
Sanded and bent the (10) 4" stand-offs already cut out and filed.
Cut and grounded down the blanks for (16) 4 inch stand-offs. Still need to be sanded and bent to shape, then sanded again.
Filed, sanded and bent the (16) stand-off blanks I cut yesterday.
Start to finish... seven additional stand-offs. I'm now finished with the stand-offs as far as I have them planned.
Cut the four pieces of tubing for the fairleads.
Clean up and set-up of jig for the upper wing center section.
Spent some time looking over the plans for the upper wing center section. Need to get the metal parts welded up and tubes cut before I can start locking things together.
Thinking about how to build the upper wing center section.
Cleaned the epoxy off the upper wing center section front and back spars. Made a set of temporary spars for the upper wing ribs to see how they aligned with the center section spars when they were threaded on the ribs.
Measured and cut the triangle support blocks for the upper wing center section. Used on the ribs.
Did research on the upper wing center section on the biplane forum... looking for those gotchas. Also checked the spacing of the upper wing spar spacing to the center section and they are almost dead on.
Just reached 2000 hours on the build !
Worked on the wing center section. Need to make an adjustment to the span build ups on the front spar.
Measured, cut and test fit the spar build ups for the upper wing center section.
Glued up the spar build up for the upper wing center section from spar.
Filed and sanded off excess glue from spar build ups.
Notched and fitted five nose ribs to front spar for upper wing center section.
Trimmed up a few support blocks for the nose ribs on the upper wing center section..
Cut angle on spar build ups then glued them to the fron spar of the upper wing center section.
Cleaned the glue off the sides of the spar (from when I glued on the build ups.)
Glued on nose ribs to upper wing center section front spar.
Need to make an adjustment to one of the ribs on the spar. (head scratching...)
Working on the upper wing center section spars.
Routed both sanding jig patterns for nose ribs on front spar of upper wing center section.
Tried using routed jig patterns for alignment and sanding. Not working. Thinking that I'll route 10 new nose ribs and cap the 5 existing ones. I'll be adding about 1 pound to the weight.
Routed 10 nose ribs. Will look at sandwiching the existing ribs next session. Need to come up with a way to align all the pieces.
Marked and cut the bottom out of the routed ribs so that they'll be able to fit around the 45 degree supports.
Tacked new nose ribs into place and marked high spots on existing nose ribs. Started to file them down. Doing this before aligning the outer two and striking lines.
Filed down the remaining original nose ribs. Struck a line to line them all up - to make sure all are in line. This didn't work. Need to use a metal straight edge.
Decided to file back the other side of the nose ribs.
Finished aligning nose ribs. Mixed up glue and tacked them into position.
Not liking what I did, I cut off all the nose ribs and started routing out the corner blocks and remaining ply to start over again.
Routed out the remaining four nose ribs from the spar.
Routed new nose ribs for the upper wing center section spar.
Drilled the lightening holes in the nose ribs.
Notched bottoms of nose ribs to fit between the build ups on the spar.
Test fit new nose ribs in place to level and square up with each other. Tweaked the notches, Nailed corner blocks temporarily in place to hold nose ribs.
More tweaking of the nose ribs. Ready to glue and lock in position.
Glued and tacked in nose ribs onto upper wing center section spar.
Looked at plans to figure out the plywood for the nose rib cover aka leading edge. Needed to make one of the nose ribs wider so that I could butt the plywood in that area so I sandwiched the nose rib with two pieces of 1/4 inch ply.