| 2ND QTR 2002 |
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| 04/11/02 - 2.7 Welded up the aft left cabane fitting and removed jig. Also made a new tailpost holder for the fuselage rotisserie. | |
| 04/12/02 - 1.5 Finished welding the aft & forward left cabane fittings.
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| 04/15/02 - 2.6 Finished welding the aft & forward right side cabane fittings. Its a challenge to weld three pieces of various thickness of metal together at once especially when they are all different shapes.
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| 04/16/02 - 1.5 CAD work on a jig design to locate the lower wing fittings
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| 04/17/02 - 1.8 Got some steel blocks cut at Pleasanton Steel on their big band saw. Also cut the 1" square tube sections for the jig.
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| 04/22/02 - 2.6 Sized and squared ends of tubing on the grinder and disk sander. Did the layout work on the table for the jig. Put some blocks down and fitted some tubes.
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| 04/29/02 - 2.2 Worked on milling the blocks for the jig down to size. | |
| 04/30/02 - 1.8 Finished milling the blocks to size. Still need to locate and drill holes with the Bridgeport. | |
| 05/02/02 - 3.0 Welded jig frame together. Restored flatness to the jig using careful application of heat with o/a torch. Jig was verified flat using a 4' level as a straightedge across the tubes at various angles. | |
| 05/04/02 - 3.5 Marked hole locations on blocks using height gage and surface plate. Also marked centers on the tops of the blocks. Drilled 5/16" holes in blocks. Came home and located blocks on jig frame. Used tubing bolted between blocks with threaded rod to keep 23.10 spacing and to make sure holes are aligned. Also used diagonal measurements to make sure blocks were square before and after welding them to the frame. Jig is now ready for fittings and attachment to fuselage.
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| 05/22/02 - 4.6 Back at it after some time off to take the kids camping etc. Set up the jig on the fuselage. Steps taken to align jig and fittings properly for tack welding: 1) Leveled fuselage. Used the Smart Level to level the fuse in pitch across the tubes 210-39 & -40. Also leveled it in roll across upper longerons between tubes -39 & -40. 2) Clamped jig with fittings loosely attached into position with .687 shim block under tube 210-27 and the .813 shim block under tube 210-29. Jig was centered on fuselage by eyeball at this point. 3) Checked for 2.0º positive incidence at the fittings using the smart level. Taped equal thickness spacers to the top of the smart level to eliminate the level from rocking on the square tubing of the jig. I had to add .013 shims (3 beer can strips) to the .813 rear shim block to get 2.0º incidence. 4) Pulled a .010 safety wire tightly from the center of 210-35 up to the center of 210-24 at FS 0.0. I then adjusted the jig so that the forward fitting blocks were centered in relation to the wire. 5) I then centered the aft fitting blocks to the wire. This required a .020 shim in the right front part of the jig. See pics. 6) Next I double checked the squareness of the jig by measuring from the tailpost holder to each forward fitting block. These dimensions were equal. Now ready to tack weld fittings on.
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| 05/24/02 - 4.0 Tack welded fittings on, enough to hold them in position for heat bending into final position. I removed the jig and bent the aft fittings and the bottom of the forward fittings. I then reinstalled the jig and bent the tops of the forward fittings. Started welding the fittings, getting about half of the left rear one done. These things take a lot of rod too, like the cabane fittings.
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| 05/26/02 - 1.0 Finished welding up the rear fittings.
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| 05/29/02 - 2.2 Welding on the front fittings, filled the gaps on the outside.
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| 06/02/02 - 2.6 Finished welding up the forward lower wing fittings. I could have done it faster, but it just took awhile since I have to let the torch cool down, the only drawback of the small aircooled torches.
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| 06/03/02 - 3.0 Started work on the flying wire fittings. First did the edge welding on the 210-57 Lug and -58 Doublers. Then adjusted the bend angle to 28º. Next I clamped them into position and tack welded them on. After heat forming the front edge I welded the front edge. Heat forming the rear edge took more heat and work to form the lug into the corner. Afterwards I welded up the back edge of the lug. I still have to tack-form-weld the doublers.
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| 06/04/02 - 2.8 Clamped then tack welded the upper tips of the doublers. Then I heat formed the edges and welded them up. Note that I checked the angles of the fittings often to make sure they stayed at 28º.
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| 06/05/02 - 1.6 Cleaned up the table, put rustlick on the newly welded areas. Did the layout work for the rudder pedal mount tubes. Note that Kevin's fuselages (and mine will too) have an extra 1.00-.035 tube at FS 5.0 for mounting the front rudder pedals. It is welded in such that the top surface of the tube is flush with the top of the 1.25" engine mount bung. Cut four tubes to rough length.
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| 06/07/02 - 2.9 Notched one end on each of the four rudder pedal mounting tubes to mate with a perpendicular 1" tube. These ends will mate with the longerons. For the two front tubes, I used the cutoff wheel to hog out the 1" cut to mate them to the 1.25" dia. bung with top tangent surfaces of each flush. I then fit the other ends to the .75" dia. 210-23 diagonals such that the bottom tangent surfaces were flush. This keeps the rudder pedal mount tubes on proper plane. I then tacked them in.
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| 06/10/02 - 2.5 Notched the rear rudder pedal mount tubes and them tack welded them in. Heat formed the inside ends of the front tubes to meet the 3/4" 210-23 tubes.
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| 06/12/02 - 2.0 Welded the rudder pedal mount tubes to the longerons only, I'll weld them to the diagonals later after putting the mounts on. | |
| 06/20/02 - 1.0 Made a doo-dad to hold the rudder pedal mounts in position for welding. | |
| 06/24/02 - 3.3 Welded the rudder pedal mount bushings on.
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| 06/24/02 - 2.1 Welded the rudder pedal mount tubes to the fuselage diagonals.
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| Quarter Total 58.8 hrs / TTD 503.5 hrs | |
| 2ND QTR 2002 |
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