August 20, 2015 Lots of clecos...
filling lots of holes...
After drilling and clecoing the bottom flange on the inner hatch cover it was kind of a repeat... of the past few days.
Cut the outer hatch cover blank 1/4inch larger all around; basically 1/2inch larger than the inner hatch blank. Filed and sanded blank before match drilling the inner to the outer. A lot of the same of what I've been doing a lot of... drilling and deburring.
Inner hatch all clecoed up.
Hatch, outside shot (with tape on it).
Hatch, inside shot (with tape on it).
Not sure how all those RV guys keep their aluminum sheets from scratching, but... I put either masking tape or that plastic floor covering over it while I'm working on the piece.
August 21, 2015 Lots of filing...
for the fit.
Spent quite a bit of time filing and sanding the flange and edge of inside blank to get them to fit nicely into the turtledeck opening.
August 22, 2015 A new skill set...
A little hesitant to begin the riveting on the turtledeck hatch. The hesitation comes from possibly screwing up all this work I've done prior to the riveting.
Took my time lining things up for the first one and... the sucker started going side-ways on me. DAMN ! Stopped before going too far with it (I'll come back to this one and drill it out later).
Lined up for the second squeeze... trying to make sure it was square all around. Looking at the part I was flattening and... when finished it looked a lot better. The back side was still a little too high and not round enough so I adjusted the squeezer and pulled the trigger on it again. After the re-adjustment it looked pretty darn good. Had time to do about a dozen rivets before needing to get ready to head out with Andrea tonight.
Before packing things up I decided to drill out the bad bad rivet. Wasn't easy even though I was taking my time. Started going nice then it JUMPED! off the head and put a small nick in the aluminum face. DAMN! Screw this... I'll take a Dremel cutoff tool and knock the barrel of it from the back-side. DAMN!
All-in-all... I'm real happy with how this squeezer is working out.
Rivet on the right is the bad bad rivet.
August 24, 2015 Fits with clecos...
rivets, not so much...
Tonight... doing a pretty good job with the rivets. Taking my time making sure I've centered the barrel of the rivet on the squeezer's head then made sure that I was squared up left-to-right and top-to-bottom. Moving a long real nice.
If I finish up in time I'll start cutting out the back insert for the pilot's seat... About two hours into the session and I'm ready to fit the hatch to the turtledeck and get moving on that seat back insert. Went to insert the hatch and... it's NOT fitting. WTH ??? Took a close look at the hatch and the bottom flange kicked out a little on the port side. DAMN! and it's riveted on !
Spent the next frickin' hour and a half sanding both the bottom flange and the turtledeck hole opening. Just pisses me off. I take all that time getting things all lined up all those days before and What The Hell Happened ? I had it all cleoced up and everything was lined up; the flange to the inside blank to fit the hole opening with room to spare and... I'm just a little pissed right now.
With a lot of sanding it fits but that's not the point. It fit beautifully before I riveted the flanges on... ahhhh, whatever...
Still looks good. Click image for close up.
December 16, 2016 Feathering...
WOW ! A lot of time has gone by since working on the tailcone... It was one of those little things I was pushing off doing. I needed to do a little building up around the opening for the horizontal stabs; the space between the front of the opening and back of the opening... along the spline. Both pieces have been cut and fitted. Only glued the one side. Other side will be done tomorrow. I'll then need to take some sandpaper to feather it. It's close now but it can be better.
No photos of it. I'll take one tomorrow.
December 19, 20, 2016 More feathering...
More work on the tailcone and attaching it to the fuselage.
Glued on the second filler piece the other day and then feathered into the existing tailcone shape.
Spent Tuesday night fitting up/grinding to fit, the bracket I made the other night.
June 10 - 28, 2019 The many iterations...
of attaching the turtledeck hatch.
I've been back on the turtledeck hatch for a while now... trying to figure out the best way of making it detachable. Thinking... and thinking... and thinking... and more thinking.
In the beginning I was thinking of having a mechanism that would insert a few pins into the bottom of it, while the top had some type of tab... I'd move a lever and the pins would either lock or release the bottom allowing me to take the hatch off for access. A lot of other ideas floated... in and out of my head. I was flipping between loocking at Tony B's books to the Aircraft Spruce Catalog... then searching the internet... Too many possible, but not possible, ways to jot down right now, and not what I finally ended up with.
I finally arrived at using the 1/4 turn fastener... better known as the Dzus fastener. I wanted to have the clean look of just the single stud inserting into the front of the hatch but special tools would need to be purchase to connect a collar to the outer panel to keep the stud/pin from falling out. This collar also has depth which... let's just say there were too many things adding up with this method that I decided to go tot he self-ejecting stud/pin that is already set up so all you need to do is drill, deburr, and rivet on. Then rivet on the appropriate spring on the backside of the bracket I made (see below) and it's ready for using.
Figuring out the bend on the inside bracket was a little bit of a challenge. Well, not the figuring out of it with the formulas... but figuring out... the bends are so close that they over-lap each other. Usually there is a space between the two bends. On these two... before the one bend totally flatens out (for the 90 degree bend) the other begin. Scratching my head as to how I was going to do it. Then... the light bulb went off. Make the first 90 degree bend... then anneal the aluminum to make it easy to make the second bend. Raise the part with a piece of plywood to the correct height. Clamp the raised part on the plywood. Clamp the bending block and then easily bang the piece over. Worked like a charm. See attached photos...
June 29, July 3 and 4, 2019 Wow WOw WOW!!!...
STOP the madness!
This entire Dzus fastener experience... it's like am I going way overboard with it? or is it just that complicated?
Figure out the total depth of both pieces to be joined. Plain stud, with all it's numerous components... or the "self eject" rivet on stud/bracket... and all its iterations. THEN try and figure out the locking spring you need for it.
Decided on the self ejecting rivet on bracket. Had one helluva time figuring out the spring attachment for it. Found that information buried somewhere on some site on the 47th page... Yeah, if you need the information, just give me a ring.
Find all that information then you want to be double, triple, quadruple sure that it's the correct stuff that you're purchasing. Not that it's a large sum of money... but you've done your do diligence now you'd like to see that all that work is right, correct, on point. Oh... wait... Add on there figuring out how to read a micrometer too. Read the .10, then there's another area of the .100, and oh by the way... then there is another area that shows the 1000. That's for measuring the depth of the pieces being joined.
July 4 - August 12, 2019 I've
STOPPED the madness!
I allowed myself to be pulled through this project at a snails (allow snails to come out of your mouth real slowly) pace. For whatever reason... it was a good thing. I'm in no rush to complete her. It's all about the learning, right?
Think about it until you know it's right. Don't accept the first thing that comes to mind. You want it simple and light weight. Think things through... until you meet all the requirements as best you can. And then throw that question out to the Gods a few times... "Is this the right path?". Ask that queston until you're sure it is...
As separate thought:
It's been sooooo long to get through this entire "how to attach the door to the turtledeck" thing. I've thouoght about this alot more than you can imagine. Yeah... investing one's thoughts into how to attach the hatch to the turtledeck. What can I say, most of the build has been like that; hours thinking the entire process of the piece over and over and over again. It's rather... um, medicinal?
I've been working on it since my last post. Just haven't written anything. It works... the door attach, not, not posting! It actually works GREAT! All I need to do is fasten the attaching plates onto the turtledeck. Before I do that I'll need to seal the turtledeck area around the mounting area. Also... figure out what to do with the aluminum plates; figure out how I want to finish them, and the hatch cover itself. All good questions of which I think I have the answers to.
January 31, 2020 It was in the back of my mind..
along with a lot of other things.
It seems like I've been kind of fooling myself for awhile now... knowing but not quite acknowledging it.
Finally following through on my "this part is finished" when in actuality... it's not finished until it is mounted onto the fuseslage, or whatever area it's being mounted to.
I just finished up on this same theory with the throttle mounting plates... now I'm back on finishing the turtledeck. Left to do; mount the turtledeck to the fuselage, and finish up the locking part of the hatch to the turtledeck. oh yeah... the flooring on it too.
Back on the mounting to the fuselage. I had already made and welded on several tabs to the upper longerons. All I thought I had to do was mount a few more then drill and attach a few anchor nut plates. Upon closer inspection... the existing tabs are too close to the edge of the turtledeck. The flat flooring that I have one the turtledeck is further away from the edge than I had planned.
Plan "B"... fabricate and mount the new tabs. Rough measurements showed that they need to be approximately 1 3/4" long. Decided to craft these out of a length of 5/8inch x .070 4130 strip stock. CAD'd up the length along with the location of the screw hole for each of the 10 tabs. Drilled holes for machine screws, match-drilled rivet holes along with counter-sinks the rivet holes... THEN cut the tabs apart. Rounded edges (filed and sanded to 150 grit). Out to the fuselge where I had clamped the turtledeck in place. A measurement showed that the tabs were close to the right length but wanted to bring the mounting holes further towards the middle of the flooring, so decided to cut them down to 1.5inches.
Tabs are now cut to length with the paper patterns burned off... ready to be aligned and welded onto the fuselage.
February 1 - 7, 2020 Mirrored? MIRRORED?...
look at that word... mirrored.
Is mirrored even a word?
(in my best Andy Rooney voice... and I don't do impersonations)
Did you ever write a word and say... that can't be how you spell it?
Not much to write home about this week...
Worked on mounting the turtledeck to the fuselage. As previously mentioned, most of the tabs were too close to the edge of the turtledeck vertical walls and needed to be re-made. This week I set about aligning and welding on those tabs.
Started off moving along real nice until I discovered a few of the existing tabs were in the way of where I needed to weld on those other tabs. So... I spent close to one and a half hours grinding off, filing, and then sanding those existing tabs.
Next day back to welding on the four remaing tabs. Popped (easier said than done) the turtledeck back on the fuselage and bolted the tail-end stringers to the tailcone. Align and clamp the turtledeck onto the fuselage for match-drilling. Back off with the tailcone so that I could drill the holes for the bolts into the tabs so that I could match-drill them now instead of later. Drilled holes... "popped" the tailcone back on and match-drilled its holes.
I wasn't able to get to two of the holes, even when I used the 90 degree angle attachment on the drill. Marked those holes for free-hand drilling. To be done on Saturday.
Alluding Side note: I'm not impressed with the location of some of the tabs for the tailcone. When welding them onto the fuselage I wasn't as precise as I could have been... Soes when you are looking at the match-drilled holes on the bottom of the tailcone they's ain't mirrored. Such is the life of a scratch-built biplane. At least mine.
February 8, 2020 I'm already focused on the belly...
Not much to write about the turtledeck...
Well... maybe a little more than "not much".
Drilled remaining two holes. Checked for fit. Reamed out the five tab holes at the rear of the tailcone... ready for monadnock clip nuts. Riveted on all (10) anchor nut plates... that's (20) rivets. T/D is ready for mounting. BOOM!