Log Entries

Project Location: AZ US

Entry Date Summary Description
Entry Date Summary Description
2005-04-13 Welding practice after adding lightweight hoses I made the light weight hoses from 1/4 " clear vinyl hose. Slipped them onto hose ends. they work great
2005-04-22 Flap and Aileron jig Welded the jig partially whil I waint for some flatstock.
2005-04-25 Bending Block this bending block is 3/4x3x6 inch hot rolled steel. I first cleaned up the edges on the table saw with a metal cutoff blade. After geting it to close dimensions with level edges, I used amill file and draw filed it smooth and flat. After draw filing , I sanded the edges on the table saw with a 7" sanding disc backed up by a cutoff blade. It works very well and I can do several operations on my table saw. After fine sanding the edges I polished them with fine scotchbrite pad. I then hand filed 4 different radiuses. One radius on each of the long corners. this allows me a bend radius of 1/8th, 3/32nds, 1/16th, and one in between i'm not sure of. It is difficult to guage a small radius.
2005-04-26 Flap drive support tube end template This template for marking the flap drive support end is made by drawing first in turbo cad, cutting it out and sticking it to 24 guage mild steel sheet, using spray adhesive.
2005-04-26 Flap drive support tube end template I used a pneumatic shear to cut out the steel template. I cut right up to the line . This shear works very well with little to no effort. The edges were then trued up to the line on the sander, and polished with scotchbrite on the drill press.
2005-04-27 Nose rib router blocks Nose rib router blocks for routering my wing ribs. After they are cut, routered, and de-burred I will use one as a backer block for forming on the main wing rib form block.
2005-04-27 Finished Nose Rib Blocks Finished nose rib blocks after bolting the two together and sanding the edges on the table saw.
2005-06-09 Nose rib pile Just a pile of squares. Next, rough shape, then to the router.
2005-06-09 Cutting out nose ribs Cutting out sheet one. Mostly nose ribs. I cut for a while, went on the computer and ordered electric shears for $39.00. I have air shears, and they are good but cut a 1/4" kurf. I will sinish blocking all the nose ribs before cutting to pattern shape.
2005-06-22 Nose ribs Routered nose ribs, 19. Had to go back and put drill bushings in the nose rib cutout template. Found it is very important to dril size trim etc allthe templates from the master. I will have to match the holes in the wing rib master form from the nose rib blocking template, so all the holes will match. Also if the hole is not exactly vertical you can only drill 3 to 5 riba at a time. The drill bushings really are great.
2005-07-01 Nose ribs Cutout and routered to size
2005-07-20 Blocked out ribs Blocked out flap nose, back, 6center ribs.
2005-07-23 Blocked out ribs Blocked out aileron nose ribs, and pocket ribs
2005-07-24 Blocking out ribs Blocked out flap nose ribs, back ribs, 6 center ribs
2005-07-24 Master wing jig Had the master wing jig made of oak. I inserted drill bushings into the holes for the jig pins and lightening hole centers. I also used brake line cut to length.
2005-07-25 Nose ribs Worked on wing nose ribs. I cut them out on a pattern made off the drawing. They should have been made off the master.
2005-07-26 Wing Master rib jig Had a full length master jig cut out of oak. I inserted drill bushings made of 4130 tubing and brake line.
2005-07-26 Wing master jig Finished wing master jig.
2005-07-26 Nose ribs, Stiffener angles. Cut 6 nose ribs and routed edges.
Cut lightening holes with flycutter.
Cut 46 1/2" angles
2005-07-26 Nose ribs, Stiffener angles. Cut 6 nose ribs and routed edges.
Cut lightening holes with flycutter.
Cut 46 1/2" angles
2005-07-28 Cut nose rib lightening holes Cut the large hole in nose ribs
2005-07-29 Cut nose rib lightening holes Cut large hole in remaining nose ribs.
2005-08-01 Cutting Lightening Holes I first tried the flycutter but ended up using a router and router pattern.
2005-08-01 Cutting Lightening Holes and Deburring First tried using the fly cutter. It worked okay but I was unhappy with this method, After cutting 46 big holes I decided to try the router method. It definately is better. After cutting the holes I debured them with a deburring tool and polished them with 3m scotch brite pads.
2005-08-01 Nose rib lightening holes I used the fly cutter first, but after cutting 46 large holes I decided to try the router method. The router method was 10 times faster. I used a deburring tool, followed by 3m scotch brite pads.
2005-08-02 Deburring Deburring lightening holes.
2005-08-03 47 Nose Ribs Cut and ready to Flange After having tried every method of cutting the ribs periphery and lightening holes, I finally settled on using a template with a 1/2" pattern copying router bit. It is by far the fastest and cleanest method. The fly cutter was horrible and took too long. One caution!!! Be verry careful when using the router. If the bearing freezes or if the router lifts up it will ruin the template and rib.
2005-08-08 Nose ribs Worked on nose ribs.
2005-08-09 Nose rib flanging Flanged nose ribs
2005-08-16 Center rib router jig Cut and routered the center rib router jig. This was cut into MDF. I first clamped the main wing rib form to the mdf, drilled the jig pin holes and lightening hole centers. I set my router up to cut with the inside edge of the cutter at 9/16" out from the master jig edge. After routing this piece I cut it out on the bandsaw, and clamped it to another MDF board, drilled the jig and center holes.
2005-08-17 Routered out center ribs I sandwiched 2 center ribs between the jig halves, and routered to shape. I found that if you get greedy with the cuts you will pay by having to remake some parts.
2005-08-18 Center ribs Worked on center ribs
2005-08-24 Center ribs Trimmed center ribs 1/8" for rear spar
2005-08-24 Center ribs edged and sanded center ribs.
2005-08-24 Center ribs Sanded edges of center ribs.
2005-08-27 Center ribs Flanged 3 center ribs.
2005-09-15 Rib stiffener jigs Made rib stiffener bending jig
2005-09-16 Rib stiffeners Bent rib stiffeners for nose ribs.
2005-09-20 Rib stiffeners Cut all rib angles out.
2005-09-21 Nose ribs All nose ribs finished. All were left long to be trimmed to final fit when installing on spars.
2006-04-15 Rod end bearing removal & restoration I purchased several rod end bearings on EBAY that had the MS21152 bearings I needed. New cost is about $57.00 each, but I got the lot for $51.00. I had to drill the rivets, remove the bearings, and clean off the crud and paint. I then soaked them in oil.
2006-05-15 Wing steel Computer design Designed wing steel parts in turbo cad. Emailed DWG files to Metalmorphosis.
2006-05-23 Gar Aero wheel dissassembly and cleanup I purchased these Gar Aero wheels from a local who didnt want them on his C-206. The Gar Aero wheel is essentially an adapter ring setup that fits onto Cleveland 6" wheels. The adapters allow you to use 10" tires. They came with 29x11x10 tires,but I will put either 8.50x10x6 tires or the 29x11x4 tires from McCreary. I stripped the paint off the wheels, adapter rings, and double puck brakes.
2006-07-18 Tailwheel body construction Started with a piece of 3" crs. Lot of cutting but that is what I could find locally. Outside diameter cut.
2006-07-18 Tailwheel body construction Drilling and boring the inside dimensions. It would be better to do this first, and cut the od last.
2006-07-19 Tailwheel Body Cut the tailwheel body out of 3" crs. Initial cut to od and drill pilot hole for kingpin
2006-07-21 Kingpin Hole Finished cutting the bearing recess and boring out the kingpin hole to proper id.
2006-07-23 Turning the tail lock cam Reversed the tw body in a 4 jaw chuck, and set the offset of 0.230" using a dial indicator. This will allow me to turn an offset cam which will later be trimmed to shape. The alternative is to cut the cam out of 0.100 sheet steel and braze it onto the tw body.
2006-07-24 Master wing jig Had the master wing jig made of oak. I inserted drill bushings into the holes for the jig pins and lightening hole centers. I also used brake line cut to length.
2006-07-26 Finished cutting cam Finished cutting the cam and remounted part in 4 jaw chuck so that the body would be centered.
2006-07-26 Cutting the cam and setup for turning the body Finished cutting the cam and setup for turning the body to dimension
2006-07-27 Machineing of Tailwheel Body Machined the tailwheel body to dimension.
2006-07-28 Finished turning body and turning bushing seat. Body was finished, and bushing seat cut. All od and id measurements were checked. Some of the measurements for the bearing seat were left undersized until after welding is done, then the body will be turned to final dimensions.
2006-07-28 Tailwheel spacer The Gar Aero tailwheel is a standard 4" wheel with a spacer between the two halves. The spacer allows a 400x4 sailplane tire to spread out at the rim and gives a wider footprint. Because I have a lathe it only makes sence to cut my own spacer. The spacer is being cut from a 5" od slug of 6061 aluminum.
2006-07-29 Tailwheel spacer 2 Finished cutting one side of adapter ring, and checked for fit.
2006-07-29 Tailwheel spacer 3 Turned side 2 of adapter ring, checked fit, checked fit of tailwheel parts.
2006-08-03 Bushings for tailwheel Needed to turn some aluminum bushings that are split so i can turn the tailwheel bushings in a threee jaw chuck and not leave any marks in the steel.
2006-08-04 Tailwheel bushings Had to make my bushings several times as I kept on overcutting on the lathe , and they were too sloppy. Finally finished them in about 20 minutes each after I learned how.
2006-08-04 Threading on the lathe Practiced turning threads on the lathe. I found that the cutters need to be stoned inorder to get a clean thread. I also found that the old timers were right about using lard as athreading lubricant. My first threads came out pretty well. I will be turning the axles next. The axles are being made long to accomodate the gar Aero wheels.
2006-08-04 Threading on the lathe Practiced cutting threads for 5.5 hrs. I will be making my axles next and will cut the 16tpi threads on the lathe
2006-08-05 Gas cap vent pieces Cut the center pieces to the gas caps to length and drilled the vent holes to a depth of 2.2 inches.
2006-08-07 Fuel cap vents threaded Finished cutting the threaded portion to size, cut the o-ring groove, and threaded the stems.
2006-08-07 Ordering parts to finish tailwheel
2006-08-07 Horn center Cut 4130 tubing, squared it in the lathe and bored out the center to 1.18 inches.
2006-08-25 Fuel Caps Turning parts on the lathe and final fit.