Finished the tacking on the stand-offs for the third stringer (made adjustments to two of the ones I had previously done). Leveled the first stringer on the left side of the fuselage.
Aligned, ground down and tacked on (4) stand-offs.
Leveled second stringer on the left side.
Worked on and tacked on four additional stringer stand-offs.
Leveled sixth stringer. Aligned, ground to shape and tacked on stand-offs for stringer.
Welded up the stand-offs on the left side of the fuselage.
Welded up the stand-offs on the right side.
Welded up the stringer tabs (front and back).
Reviewed stand-off layout to confirm lengths of stand-offs.
Marked lengths of stand-offs. Went to attach stringers and saw that I still needed to attach the additional stand-offs for the formers at station 24.o.
Tacked on four former stand-offs. Welded on all eight of the former stand-offs.
Confirmed alignment of all stringer stand-offs and marked locations of stringers and cut-backs (1/8").
Re-aligned one of the stringer locations then marked all stand-off cut-offs. Cut down top, port-side stand-offs.
Cut down the rest of the stand-offs to size.
Spent a little over an hour messing with the fuselage trying to flip it (one guy flipping a 100 lb frame in a one car garage trying to avoid hitting a Harley). Not logging 1.2hrs of time for just flipping and leveling a fuselage.
Made the gusset pattern for the bottom former at station 10.5. Traced, cut, ground down, filed and sanded all four gussets.
Needed to make four additional gussets for Station 10.5. Made them.
Evaluated what I needed to do again... after being sick with something for about 2 weeks.
Confirmed gussets for stations 10.5 and 27.0. Started drilling lightening holes in gussets for 27.0. Took forever to drill three of them.
Drilled ligthening holes in former gussets.
Made jig for belly former at station 27.o then tacked in place.
Aligned and tacked on the belly former at station 27.o. Reattached the firewall blank.
Tacked on the additional gussets on station 27.o former. Tried fitting up the former pattern at station 10.5 but couldn't get it to work. Thinking maybe of only doing the former up six inches on the back side of the front landing gear attach point.
Worked on the belly former at station 10.5. Needed to get the angle from the firewall to station 27.o so that I could form up the correct radius at station 10.5. Tried using a few sheets of laminate. They worked somewhat but bowed. Found a piece of thin masonite and attached it using screws and straps. Cut the pattern for cutting the holes on the gussets.
Tweaking the former for the belly of station 10.5 (just about there). Modified the four gussets to fit onto the upper longerons.
Re-made one of the gussets for station 10.5.
Tacked on one set of gussets at station 10.5. Tweaked the former and then tacked it to the two gussets.
Squared up former at station 27.o and tacked the second set of gussets onto the fuselage then tacked the gussets to the former. Determined what I was going to do with the former at station 49.o6. Cut it to size. Squared it up to the fuselage and tacked it in place.
Made six more front and rear tabs for the stringers to lock into.
Started working on fitting up the belly stringers. More thinking than doing tonight.
Welded on 3/8" tube to back-end of fuselage to mount center stringer tab. Filed all three tabs to fit and then tacked on.
Marked former 27.o for stinger tab locations. Filed tabs to fit then tacked on.
Flipped the fuselage. Temporary attachment of front and back of stringer. Turned on the laser level and started leveling. Cut belly former for station 77.o and tacked onto fuselage.
Most of the alignment boards for the stand-offs were on the wrong side for easy welding. Spent all this time on re-aligning the stringers with the board on the correct side.
Fine tuning of stringer alignment. Notching stand-offs and tacking into place. Also decided to eliminate the former at station 105.o and use just stand-offs. (less weight and looks like it will be stiffer than the oddball)
Re-check alignment of stringer. Confirmed then welded center stand-offs onto fuselage. Needed to figure out stand-off lengths for stations 49.o6 and 77.o. The rest of the lengths fall to the natural bend of the aluminum stringer.
Leveled the stardboard stringer. I'll be tacking it on tomorrow.
Tweaked the stand-offs and tacked them on the starboard side.
Leveled the last belly stringer.
Last set of stand-offs for the belly aligned and tacked onto the fuselage
Started cutting down the belly stand-offs to size... then, I needed to re-level and tack one of the stand-offs back on when the tack on it broke off from me grinding it.
Finish welded the belly stand-offs.
Finish welded the forward starboard gussets station 10.5 and station 27.o. Continued cutting down belly stand-offs.
Cutting down the belly stand-offs to size and cutting the angles from the step to the foot. All cut... just filing to finish them off. Still need to sand to a smooth finish.
Filed and sanded the belly stand-offs to a smooth finish. Attached stringers onto stand-offs with tape... for now. NICE !
Reshaping the stand-offs on the starboard side. About 1/2 of them needed trimming to prevent part of the stand-off from possibly hitting the fabric.
Filed down and sanded smooth the belly stand-offs that I cut to size yesterday.
Figured out... then modified two stand-offs to work as the rear stringer tabs.
Positioned and welded on the two new rear tabs for the bottom, side stringers. Started to trim down the legs on the port side stand-offs.
Confirmed measurements of port stand-offs then trimmed, filed and sanded the additional nine. Created new pattern for upper former at station 46.o9.
Looked over R plans to see where things needed to be connected to the longerons. Went out to the garage and started thinking of what I needed to do at those locations for building up the longerons for the shape. Station 27.o need to move the gussets for the former further towards the center. Made pattern, cut and sanded smooth all four.
Welded on the four gussets onto the upper former at station 27.o. Cut and fitted up a few diagonals between the side and upper formers at station 27.o. Figured out what I'll be doing for the "false" upper longerons between station 27.o and 49.o6.
Found an 8ft length of 7/8 inch tubing to use for the false longerons. Figured out exactly what I would do and the measurements. Decided to hold off and buy some .o35 instead of using the .o49 I have. I'll save close to a pound on just the four pieces.
Positioned and welded on fairleads for the rudder cables.
Notched the two rear false longerons. These are the ones that I'm building out from the fuselage to give it a more rounded look. (Note: this was a lot of notching.)
Cut all three pieces for the forward starboard false longeron. Notched both stand-off tubes.
Cut second set of false longeron stand-offs. Took about an hour to tweak the first set.
Welded on caps to false longerons. Tacked both onto fuselage.
Tweaked the notches in the rearward false longerons.
Notched stand-offs for the rear portion of the false longerons.
Messed up both stand-offs I made the other day. Re-made them.
Made caps, welded then filed and sanded the ends of the rear false longerons. Postioned and tacked them into place.
2300 hours !!!
Started welding up false longerons.
More welding of the false longerons.
Welded on stab wire attach straps and finished welding on fairleads.
Flip fuselage and just about finished welding the false longerons. I need to flip it back over to finish up the rear false longeron on the front end. (I extended the other side for an easier weld around the front joint.
Looked over the plans to see where the top rear strut attaches (Station 24.o) Held it up against the fuselage and discovered I needed to move one of the gussets for the former at that location. Moved it and saw I didn't move it enough. Had to cut the tack welds again and reposition and tack.
Confirmed angles on rear strut attach brackets. Drilled under-sized holes. That's it.
Cleaned up both sets of rear strut brackets before welding them up. Welded up one set.
Welded up the 2nd rear strut bracket and finished the welding up on the two stab wire attach straps.
Re-made/bent upper former for station 49.o6.
Researched how fuselage sides need to be made at bottom wing juncture. Took a stab at looking at the Model 14 on the Steen sight. It's what I needed.
Cut and banged the third piece of the 3-piece rear strut attach. Both are ready to be welded up.