Tack welded both rear strut attach fittings. Ground down and fitted the upper former for station 49.o6. Tacked it into place. Had to grind off tacks on one side and re-attach (it was slightly off)
Finished welding up the rear strut attach brackets.
Start working on the turtledeck. Seeing if the plywood would bend to the shape. Figuring out how I'm going to do what I have designed.
Drilled all eight holes in rear strut attach brackets then reamed them to 5/16".
Re-made the rear 2-piece turtledeck former (station 137.5).
Cut-off the former at station 89.49 so that I could reform the lower section. Tack both it and the new turtledeck rear former onto fuselage. Cut off the former I had at station 133.o. Started forming up what the final shape of the turtledeck will look like.
Re-worked the former at station 105.o. Easily put in over six hours on this.
Cut forward turtledeck former. Turned out to be a test piece on homebuilder's grade ply. Should have added height to it in order to make an angled cut. See blog.
Used aircraft grade 1/4" plywood to cut the center and the rear formers for the turtledeck. Looks good.
Figuring out what I need to do with the upper wing fuel tank. Make a mock-up of it to sketch out the location of the pieces.
Reviewed the plans and made a list of what I need to do. Thought long and hard about re-making the outer metal ribs for the upper wing fuel tank.
Decided to re-make those two metal ribs for the upper wing fuel tank. Cut the blank, cut the shape, filed the sides and bent the first one in about two hours. Cut the blank then cut the shape for the second one.
Finished the re-make of the two upper wing fuel tank outer, metal ribs.
Figuring out and confirming the size of the upper wing fuel tank.
The last three days I've been reviewing the upper wing center section drawings. Tonight I pulled out the pieces I have. Test fitted what I could. Saw what I needed to do. Made a To-Do list. I think I'm ready now.
Measured, cut and cleaned the ends on 10 of the tubes for the upper wing center section. Still need to cut those .120 tubes.
Cut the 7/8 x .12o tubing for the upper wing center section. Went over to Whitey's to put them in the lathe to cut down to size and square up the ends.
More work on the upper wing center section. Re-cut one of the 20 13/16 inch 3/4 x .o35 tubes. Fit the end caps on to both 20 13/16 inch tubes. Review of plans again.
Measured and cut the (8) pieces of aluminum "L" brackets for the center section of the upper wing. Then squared off by filing.
Marked all the aluminum "L" brackets for hole locations.
Fitting up the wing brackets for the upper wing center section. Need to plane down the spars to fit the brackets.
Planed down the forth and final spar build up for the forth and final wing bracket on the upper wing center section.
Sanded the edges smooth on the first of four upper wing center section wing brackets.
Sanded the edges of the second upper wing center section wing bracket.
Sanded the edges of the third upper wing center section wing bracket.
Sanded the edges of the last upper wing center section wing bracket.
Reamed out all the 1/4inch holes on the upper wing center section wing brackets.
Put the paper pattern up to the forward former on the turtledeck and saw it was slightly different. Re-made the pattern and then traced it onto the ply I just received.
Made jig to sand angle on front turtledeck former. Rough cut and sanded to size that former.
Cut the saddle gussets for the turtledeck.
Working out what I'm doing with the turtledeck. Think I'm changing it up again. Making an additional former for station 130.o. Thinking now of just making a box frame with the stringers and then make a baggage comparment separately.
More work on the turtledeck. Cut down the wood former at station 105.o. Modified and cut out the wood former for station 130.o. Figured out what I'll be doing with it... finally.
Traced and cut out the front false former for the turtledeck. Thinking out the details...
Made additional saddle gussets for the turtledeck bulkhead. This included making a dual saddle gusset for the stringers at the intersection of the upper and lower halves of the turtledeck.
Worked on forward bulkhead for turtledeck; made additional saddle gussets and marked for alignment of gussets when glueing up.
Glued saddle gussets to forward turtledeck bulkhead.
Drilled all (32) 1/4inch straight as arrow match-drilled holes into upper wing center section spars for wing brackets.
Cut a new 2-piece false former for the turtledeck bulkhead. A lot of tweaking.
Spent an hour preping and glueing up false formers to turtledeck bulkhead.
Made the pattern for the floor of the turtledeck. Marked pattern on 3/32 ply. I'll route it out tomorrow.
Routed the floor for the turtledeck.
Routed the openings in the turtledeck floor.
Worked on cutting the former supports for the turtledeck. Re-made the most rearward former (was a little too thin).
Cut additional former blocks. Cut the angle on the front block. Glued three into position.
Glued the additional former blocks onto floor of the turtledeck. Drew up the pattern for the baggage door opening (after a lot of deliberation).
Figuring out the ply lay-up for the turtledeck. Thinking I need to run stringers underneath the ply for support?
Figured out the former for the inside of the baggage compartment. Cut it out of 1/4inch ply and test fitted. Still need to route the "inside" out of it.
Made the pattern and cut out the oepning in the former that is inside of the baggage area. Also cut the first of two former blocks for the former I'm working on.
Cut and glued on the final former block on the turtledeck baggage compartment floor. Started playing with the vertical tail to see what looks right. Need to weld the metal ribs onto tail group so that I can see what I need to do with the stringers in that area.
Quite a few things done today; tweaked the leading edge of the vertical tail, cut the mounting plate for the forward part of that leading edge that will be welded to the plate I also made for the rear turtledeck former, repositioned the rear turtledeck former and tacked into place, fully welded this former and the metal bulkhead former. Re-made a rear wood test former for the bagage compartment. After figuring out the shape and cutting the test piece... it works so I'll be making it out of actual aircraft grade ply when it arrives.
2400 hours !!!
Welded on the mounting plate for the forward edge of the vertical tail leading edge. Sized, cut, pounded to shape and mounted the forward vertical tail post. Fitted and cut to size the leading edge of the vertical tail.
Re-shaped the test former and did a test fit.
Made the paper pattern to make the plywood pattern to route the hole for the baggage door opening.
Cut out baggage door opening jig then routed out the baggage door opening. I then sized it up on the fuselage. Checked to make sure that the test former I made the other night (for rear of baggage compartment) worked.
Routed new former for rear of baggage compartment.
Spent all this time messin' with trying to get the right shape for the final wood former for the turtledeck. Close... but not there yet.
FINALLY figured out pattern for last former for turtledeck. Transferred to wood. (still need to cut out wood pattern)
Routed out last turtledeck former. Notched formers in baggage area for attaching spanning supports for the plywood covering.
Notched for forward notches on the bulkhead of the turtledeck and cut the two spruce supports to length. Cut out two paper patterns for the saddle gussets that will go on the rear of the baggage compartment; extra glueing support for the spanning supports.
Cut the two front notches in the turtledeck bulkhead former. Cut the two rear saddle gussets too.
Cleaned up the notches in the baggage area bulkhead. Cut one of the saddle gussets for the forward stringer attach area.
Re-made the first spanning support saddle gusset (1hr) then cut the first test saddle gusset for the second then made the finished gusset.
Notched and fitted the spline/backbone into all the turtledeck formers.
Put the angled edge on the spline.
Started trimming down the former support blocks - cutting the angles on the them.
Trimmed angles on turtledeck former blocks to conform to the ply covering.
Began making patterns for the turtledeck's ply covering. Discovered that I need to make in four pieces; the front top and front bottom, the back top and the back bottom. Made ply tests for the bottom starboard side.
Made first, final turtledeck plywood covering and fitted up to turtledeck.
Made second, final ply covering for turtledeck and then routed the former doubler for glueing up the front edge of the back ply pieces.
Cut and rough fitted the lower, back ply covers for the turtledeck baggage area. Glued former doubler together then glue front and third former on turtledeck.
Needed to rethink some things. The turtledeck is back a little too far and gets in the way of the forward attach of the stabs. Cut down the length of the turtledeck. Need to cut the welds on the rear metal turtledeck former and move forward.
Re-made the rear wood former for the turtledeck. Cut and fitted the former block for the same former. Glued in the second and forth formers.
Re-made rear wood former. Yes AGAIN (notch at top was too large). Glued on both the rear former and the ply just in front of it.
Needed to shave the sides of the spline (with chisel). Cut and fitted back corner block for rear former of baggage compartment. Started gluing in spline and spanning supports.
Gluing up more of the turtledeck.
More gluing on the turtledeck.
Glued in spanning support forward saddle gussets. Trimmed and sanded down rear spanning supports, sides of 4th and 5th wood formers, added filler to front end of splne trimmed down rear of base.
Cutting, fitting up and gluing on of the base glue blocks for the lower ply on the tutledeck baggage compartment
Glued and clamped on first ply cover; front, bottom starboard piece.
Un-clamped the first ply cover. Aligned, glued and clamped the second ply cover; foward, lower, port piece.
Fitted and glued on rear, lower, port ply.
Fitted and glued on starboard, rear ply.
Figured out and cut the ply patterns for the remaining four upper pieces on the turtledeck baggage compartment.
Cut the four remaining ply pieces for the turtledeck. Fitted up and trimmed to size one of those four to the turtledeck.
Trimmed and fitted the remaining three ply pieces.
Had time to go do and look at the turtledeck to figure out how I was going to clamp the forward, upper, port ply.
Glued and clamped/nailed forward, upper, port ply onto turtledeck.
Glued and clamped on forward, upper, starboard ply.
Started sealing inside of turtledeck with L-26 sheathing epoxy. Solution thickened before I was able to finish.
Glued and clamped on rear, upper starboard ply.
Glued and coamped on rear upper port ply.
Needed to go back and re-glue what I just glued. Apparently the block I used to hold the ply against the spanning support didn't curve to the shape of the turtledeck and it didn't glue to one section of the support.
Sanding excess glue and trimming final mounted ply.
Made mounting tabs for turtledeck.
Aligned and tacked mounting tabs onto fuselage.
Welded on all eight tabs.
Figuring out the location of the stringers on the turtledeck. Placed them on the startboard side to see how it will need to fair into the tail. Looks good !
Figuring out the tail end of the turtledeck stringers; how they will merge and how I will connect them to the fuselage.
Messin' with the stringers for the turtledeck. Still trying to figure it all out.
Figured it out. I'll be capping the back with a tail cone for a smooth transition. Had to see where I would end the bottom stringer (just before the horz. stab)... things like that.
Staring at the fuselage figuring out more stuff.
Cut and fit ply for tail cone.
Glued on ply (coated inside of ply with T-88).
Made pattern for tail cone inner cap (to keep the stringers in place).
Attempting to make a quality tail cone inner cap. Three down... none are a keeper.
Made the tail cone inner cap... for a forth time. I'm happy with this one.
Began cutting and fitting the first layer of stringers on the starboard side of the turtledeck.
Cut and fitted the first layer of stringers on the port side. Still need to do the doubler stringer on both the port and starboard sides. Cut and fit the second layer of stringers on the starboard side.
Figured out and cut the first of two sets of the double-stringers. Made the ones for the starboard side.
Cut and fitted second set of double stringers for the turtledeck.
Work on the turtledeck stringers. Cut both 2nd layer stringers for the starboard side then adjust the others on the starboard about 6inches shorter. This will allow a better turtledeck to fuselage curve.
Cut the remaining second layer stringers for the turtledeck's port side. Also cut and fitted the port side spline to tail cone stringer.
Final layout of the starboard side stringers. Laid down the first layer. Will let it sit over night. Give it a day to make sure I'm happy with it. Figured out and drew up the pattern for the metal former that will support the stringers between the rear wood former and the tail cone.
Laid out the stringers on the port side; final lay-up. Will glue up later.
Making spacers for the top turtledeck stringers. The bow tht they make lift them off the plywood. Formed the triangluar former for supporting the rear turtledeck stringers. Figured out how I want to make the vert stab cross brace.
Made the jig and cut the pieces to make the vert stab cross piece.
2500 hours !!! I was suppose to have been done by now.
Welded the vertical stab cross piece. Dismantled turtledeck so that I can align and weld on the leading edge of the vert stab and vertical stab cross piece.
Aligned and tacked on the leading edge of the vertical tail. Had it real close a few times... wanted it closer. That's what took so long.
Working on the vertical tail: welded the top, front tube to former, vertical post complete, leading edge to vertical post partial, bottom metal rib aligned and partial weld, cross brace support aligned and tacked.
Trimmed, fitted and welded on the top metal rib to the vertical tail.
Worked on the stand-offs for the turtledeck stringers. Needed to figure out where the horizontal tail mounts would be and needed to figure out the stand-offs to work around those mounts.
Put the stringers back on the turtledeck to figure out the additional stringer supports I need to make. Which... is ten, similar to the ones I made for the fuselage stringers in the tail area.
Figuring out the stand-offs for the turtledeck rear stringers. Drew them up on DetaCAD. Will print tomorrow.
Cut out, ground down and filed smooth 10 stringer stand-offs.
Bent the stringer stand-offs to form bracket that the stringers will attach to.
Modified the stringers on the turtledeck. I added additional pieces of 5/16inch cap strip where they need to attach to the stringers. This will allow me to pin/bolt/tie the stringer on and have plenty of room to do it. Also started figuring out how the two stringers coming off the spline will "flow" into the spline.
Working out the spline to tail cone transition. Also cleaned up the additional wood pieces I glued to the stringers last night.
Notched the two upper stringers; the ones from the spline to the tail cone.
Made supporting bracket for above stringers from a 5/8inch retangular tube. Just right for the 5/8inch tube.
Welded on stringer bracket. Finished welded a few of the small metal formers I had previously tacked in place in the tail area.
More tweaking of the two upper stringers on the vertical tail. Also made and glued a saddle bracket onto the third wood former on the turtledeck.
Aligned and tacked on 1/2 of the turtledeck stringer stand-offs.
Aligned and tacked on the remaining turtledeck stringer stand-offs. Now to finish weld them.
Finished welded the 10 stand-offs I aligned and tacked on yesterday. Aligned and tack on the two stand-offs for the double-stringer.
Made a few brackets to hold the double-stringers in place on the stand-off... then discovered I had made two extra small stand-offs that I used on the metal formers in the tail cone area. Used them instead. (duh!!!) Aligned, tacked and welded both on the stand-off.
1.3hrs - Sanded the inside of the turtledeck. Undoing the crap that built up when I tried using the L-26 sheathing resin.