tag:blogger.com,1999:blog-39308660497427663502024-03-13T02:09:48.326+00:00G-BRIH RestorationWelcome to this blog following the restoration of my 61 year old Taylorcraft BC12D G-BRIH (formerly NC43762). My intention is to document the restoration process with appropriate photographs partly as a record for myself, but also for the benefit of other vintage aircraft owners.Andy Dukehttp://www.blogger.com/profile/09382605630219566798noreply@blogger.comBlogger34125tag:blogger.com,1999:blog-3930866049742766350.post-46228259643783662142010-05-16T17:27:00.005+01:002010-05-16T22:21:36.491+01:00A New Instrument Panel<span style="font-size:85%;"><br /></span><div><span style="font-family:verdana;font-size:85%;">I had always planned to replace IH's instrument panel and with in mind had managed to purchase one through the Taylorcraft Foundation a couple of years before the start of the restoration. The new panel came complete with holes cut for the control yokes but all the instrument and mounting holes would need drilling.</span></div><br /><div><span style="font-family:verdana;font-size:85%;"></span></div><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMrRQKR37wHidaOMXv0mUz2qWdBhtuJpMAeOemBCXKBqmYWx0IS4rX-HYMVLnQTz4ljhTjciNhFEwkZaEyLkUD3p8_xZR7HVeotdBhQw_5b70oc6NbZmCxW0BHwhtaHgRIPiHUmE3mRXc/s1600/panel-(1).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5471910787034813058" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMrRQKR37wHidaOMXv0mUz2qWdBhtuJpMAeOemBCXKBqmYWx0IS4rX-HYMVLnQTz4ljhTjciNhFEwkZaEyLkUD3p8_xZR7HVeotdBhQw_5b70oc6NbZmCxW0BHwhtaHgRIPiHUmE3mRXc/s200/panel-(1).jpg" /></span></a></div><br /><div><span style="font-family:verdana;font-size:85%;"></span></div><br /><div><span style="font-family:verdana;font-size:85%;">The instrument centre positions were marked out on the new panel and 1/8th inch pilot holes drilled. The pilot holes were opened out to 16mm with a sheet metal step drill so that the main instrument holes could be cut out with a special hole cutter.</span></div><br /><div><span style="font-family:verdana;font-size:85%;"></span></div><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-a0NWlfuRK-EAuARrd_R-NthSa2kTD1s5jxU2_U5Uoyoz-F0lpZL1MX25Ak1xF1ARB0MUiSe5lJ_nyd6l-Lcm5hAwDItyKMPwuojuWkSFCXtV_z0yC2D3mTsq2aGjLI77epMpfzRle6c/s1600/panel-(2).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5471910791777296322" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-a0NWlfuRK-EAuARrd_R-NthSa2kTD1s5jxU2_U5Uoyoz-F0lpZL1MX25Ak1xF1ARB0MUiSe5lJ_nyd6l-Lcm5hAwDItyKMPwuojuWkSFCXtV_z0yC2D3mTsq2aGjLI77epMpfzRle6c/s200/panel-(2).jpg" /></span></a></div><br /><div><span style="font-family:verdana;font-size:85%;"></span></div><br /><div><span style="font-family:verdana;font-size:85%;">The cutter clamps either side of the metal sheet and as the nut/bolt are tightened up, the hole is bitten out of the metal. This leaves a perfectly sized, clean hole fo the instrument. The cutter is reversable for both 3.1/4" and 2.1/2" holes which covers the ASI, Tacho, Altimeter and mag switch but not the Oil Pressure and Temp gauges.</span></div><br /><div><span style="font-family:Verdana;font-size:85%;"></span></div><br /><div><span style="font-family:verdana;"></span><span style="font-family:verdana;"></span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRTBEcxLMsE-ubqotAbXGG1-zlRGBbLPqMfcwF9xkFS1GOiM4yip2HLR7dECPSufWv9d_6Cvb-9-xiv6qVRcMcYoh_AcYj1fA4jHbL3x-d7S8yJCrms2ySGMIbvjv-Wh3tZHlnfMAq970/s1600/Panel-(3).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5471910795715335234" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRTBEcxLMsE-ubqotAbXGG1-zlRGBbLPqMfcwF9xkFS1GOiM4yip2HLR7dECPSufWv9d_6Cvb-9-xiv6qVRcMcYoh_AcYj1fA4jHbL3x-d7S8yJCrms2ySGMIbvjv-Wh3tZHlnfMAq970/s200/Panel-(3).jpg" /></span></a><span style="font-family:verdana;font-size:85%;"> </span></div><br /><p><span style="font-family:verdana;font-size:85%;">With the holes cut, the mounting holes are drilled using a drilling template.</span></p><p><span style="font-family:verdana;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIlnE0PvIbtoieh3BbKVCgNQyxJzngslFLEBySqa3b4Z_35rJfnf1A8I4CuhrPIWFd-NoO-98LeZgqisB04cnTm5Jkm7mwv95QA62jzmTiZpvhXAITvIeMQnsn9DE6P_NHR1tE9L7f1uY/s1600/Panel-(4).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5471910800541896162" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIlnE0PvIbtoieh3BbKVCgNQyxJzngslFLEBySqa3b4Z_35rJfnf1A8I4CuhrPIWFd-NoO-98LeZgqisB04cnTm5Jkm7mwv95QA62jzmTiZpvhXAITvIeMQnsn9DE6P_NHR1tE9L7f1uY/s200/Panel-(4).jpg" /></span></a><span style="font-size:85%;"> </span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuLQmo2Q_1Xos2YXw0hcwGIm1ubxqihEihnJLgB_0jBKEhnXN05QtTTmWKvsIadhLCDzAYsfKq_i0R7a41KFVGPY-WtbllhocvsROy1POC0zhZl1DgsEQoPnjevdfeOIWxGdQtn2jMdJ4/s1600/Panel-(5).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5471910803558433778" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuLQmo2Q_1Xos2YXw0hcwGIm1ubxqihEihnJLgB_0jBKEhnXN05QtTTmWKvsIadhLCDzAYsfKq_i0R7a41KFVGPY-WtbllhocvsROy1POC0zhZl1DgsEQoPnjevdfeOIWxGdQtn2jMdJ4/s200/Panel-(5).jpg" /></span></a><span style="font-size:85%;"> </span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_e_C8w6IYiR_fT7qQZCMOqEICcAOMiJ732cd4hqAIpdGAsAIXlJOfjOsamRRvwg1hj1twkOxy7PgtjVMrQxsJcehyphenhyphenJn8sl9nzENbZk7_5PnAiPH9OSMOEymz5qV6DqDzy34HCisFH4KU/s1600/Panel-(8).jpg"><span style="font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5471939548044967010" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_e_C8w6IYiR_fT7qQZCMOqEICcAOMiJ732cd4hqAIpdGAsAIXlJOfjOsamRRvwg1hj1twkOxy7PgtjVMrQxsJcehyphenhyphenJn8sl9nzENbZk7_5PnAiPH9OSMOEymz5qV6DqDzy34HCisFH4KU/s200/Panel-(8).jpg" /></span></a></p></span><div><span style="font-size:85%;"></span></div><div><span style="font-size:85%;">The altimeter needs a cutout for the subscale setting knob. For this I made a template from an offcut of aluminium sheet, nibbling and filing the aluminium away until I got a good fit with the instrument. Once this was achieved, the template was used to mark out the area to cut away on the panel itself. The final result is shown above.<br /></span></div><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-FfCM5IRzivMFQR3hxTU74G-_SE4d5wWX4KK4FOkzXaqZ3JJzYjrzyKm97fpY2zqEsq4Hgsqc_qyZ3nsAwO06JtUTJsFTbr_ST21hNjuJwm44-RffkNQnivyHlw23WO6m9ud2IXpP8ts/s1600/Panel-(6).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5471910977736350386" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-FfCM5IRzivMFQR3hxTU74G-_SE4d5wWX4KK4FOkzXaqZ3JJzYjrzyKm97fpY2zqEsq4Hgsqc_qyZ3nsAwO06JtUTJsFTbr_ST21hNjuJwm44-RffkNQnivyHlw23WO6m9ud2IXpP8ts/s200/Panel-(6).jpg" /></span></a><span style="font-family:verdana;font-size:85%;"> </span></div><div><span style="font-size:85%;"></span> </div><div><span style="font-size:85%;">The two holes for the Oil Pressure and Temp gauges had to be cut using a fly cutter. This is a little more tricky because getting the right size hole is more fidley, or it is with the fly cutter I have, so plenty of trials were done on pieces of scrap before committing the the panel itself.</span></div><div><span style="font-size:85%;"></span> </div><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUHLf9iJKLx-6-7fxdeEfaAAi2iy1MnvWdzybatd0xgJCwDqaYS71zPbWmp447cXmXNczjgQMU5gqmTIxD67WCNf8EJ_UfB_d6R-_qWqdhjghUex5q1MlbrRZtFElUFht-4J-pJtmkczI/s1600/Panel-(7).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5471910977962464162" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUHLf9iJKLx-6-7fxdeEfaAAi2iy1MnvWdzybatd0xgJCwDqaYS71zPbWmp447cXmXNczjgQMU5gqmTIxD67WCNf8EJ_UfB_d6R-_qWqdhjghUex5q1MlbrRZtFElUFht-4J-pJtmkczI/s200/Panel-(7).jpg" /></span></a><span style="font-size:85%;"><span style="font-family:verdana;"> </span></span></div><span style="font-size:85%;"><span style="font-family:Verdana;"></span></span><br /><span style="font-size:85%;"><span style="font-family:Verdana;"></span></span><br /><span style="font-size:85%;"><span style="font-family:Verdana;">Monting holes were then cut with the panel in place in the cockpit. I still have holes to cut for the radio stack and Mic and Phone sockets but these will be left until I have finalised the radio equipment that will be carried. </span></span>Andy Dukehttp://www.blogger.com/profile/09382605630219566798noreply@blogger.com0tag:blogger.com,1999:blog-3930866049742766350.post-58792469830973871332010-03-28T16:44:00.009+01:002010-03-28T17:48:36.405+01:00A new Battery Box<span style="font-family:verdana;"></span><span style="font-family:verdana;font-size:85%;">Mid February and the fuselage frame had one coat of epoxy primer applied. I would have liked to get to the stage of painting the acrylic top coat but have decided to wait until the warmer summer months as it will be easier to apply with the warmer, dryer weather. In the mean time I managed to give the frame a second epoxy coat, spray up some of the tail surfaces and start to fit out the cockpit area. This will be a first fit process allowing me to construct a new interior, fit it and make sure everything works before I finally top coat the fuselage. The sort of items that new working on are the new instrument panel, seats, baggage sling, parcel shelf, harnesses, stringers, trim system etc ... the list is endless.</span><br /><br /><span style="font-family:verdana;font-size:85%;">To begin, I fitted the new floorboards and bulkhead forward of the seat. This is where the new battery box will be sited (previously it was under the seat sling which was difficult to access when changing batteries). I spent some time pondering various designs of battery box, most of which were prototyped in card prior to settling on the final design.</span><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj3L99y5ie-GZ-WbejJPj3DtA_52TduyUvqBJhcruDR0QcqE7ndr0Ueqv8Uu2H0owibxRUehoh9_BovdKUJEdZo6Wtr4WOMFHTeNYk8MX_pIaG9XSzmVHiye3xksIG3hUZx0XXmdD0tKo4/s1600/BatteryBox-(6).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5453712204980320754" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj3L99y5ie-GZ-WbejJPj3DtA_52TduyUvqBJhcruDR0QcqE7ndr0Ueqv8Uu2H0owibxRUehoh9_BovdKUJEdZo6Wtr4WOMFHTeNYk8MX_pIaG9XSzmVHiye3xksIG3hUZx0XXmdD0tKo4/s200/BatteryBox-(6).jpg" /></span></a><span style="font-family:verdana;"></span><br /><span style="font-family:verdana;font-size:85%;">One of the earlier box designs; looks OK but how do you lift the batteries out?</span><br /><span style="font-family:Verdana;font-size:85%;"></span><br /><span style="font-family:Verdana;font-size:85%;">The final criteria for the battery box was:</span><br /><ul><li><span style="font-family:Verdana;font-size:85%;">Should be lightweight.</span></li><li><span style="font-family:Verdana;font-size:85%;">Should be simple to construct.</span></li><li><span style="font-family:Verdana;font-size:85%;">Should protect the batteries and wiring from accidental damage from pilot & passenger.</span></li><li><span style="font-family:Verdana;font-size:85%;">Should take up minimal space in the cockpit.</span></li><li><span style="font-family:Verdana;font-size:85%;">Batteries should be easily replaced.</span></li><li><span style="font-family:Verdana;font-size:85%;">Machine screws/anchor nuts should be used to secure the battery box.</span></li></ul><p><span style="font-family:verdana;font-size:85%;">The final design consists of a simple tray made from aluminium angle which will be secured to the floorboards with machine screws. The underside of the floorboards will have an aluminium plate, with anchor nuts <span id="SPELLING_ERROR_0" class="blsp-spelling-corrected">riveted</span> on, bonded to the floor. The two batteries will sit in the tray and be enclosed by an aluminium cover fixed to the floor and bulkhead in a similar <span id="SPELLING_ERROR_1" class="blsp-spelling-corrected">fashion</span> to the tray.</span></p><p><span style="font-family:verdana;font-size:85%;">The tray and cover sit over the centre join of the floorboards and will help secure them as there is no fuselage framework at this point to support the floor.<br /></span><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhpvKp8QTeekErATAvrq2MdG9BtM4M3yy-te7ez8vskmWBl560_j1lwwRsGcurwA3BwSkS0WwPywZYwLyVLANle4SgCmoVGyYP4Mu8aKXVxF3knf8junbmFh7YyIBaO8LIu1Sa-L4f9sF8/s1600/BatteryBox-(7).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5453718856028039922" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhpvKp8QTeekErATAvrq2MdG9BtM4M3yy-te7ez8vskmWBl560_j1lwwRsGcurwA3BwSkS0WwPywZYwLyVLANle4SgCmoVGyYP4Mu8aKXVxF3knf8junbmFh7YyIBaO8LIu1Sa-L4f9sF8/s200/BatteryBox-(7).jpg" /></span></a><span style="font-family:verdana;"></span><br /><span style="font-family:verdana;font-size:85%;">The tray will take two 12V, 7Ah batteries. The corners were simply cut at 45 degrees with a <span id="SPELLING_ERROR_2" class="blsp-spelling-corrected">band saw</span>.</span><br /><span style="font-family:Verdana;font-size:85%;"></span><br /><span style="font-family:Verdana;font-size:85%;">The cover was marked out on a single sheet of 0.032 NS4 <span id="SPELLING_ERROR_3" class="blsp-spelling-corrected">aluminium</span> (equivalent to 5251 H22) using a fine permanent marker (not pencil), remembering to add between 1/16" and 1/8" for the bends. All fixing holes were <span id="SPELLING_ERROR_4" class="blsp-spelling-error">pre</span>-drilled prior to bending. The sheet was <span id="SPELLING_ERROR_5" class="blsp-spelling-corrected">guillotined</span> and the main bends made on a sheet metal folder. Some of the bends had to be done by hand later.</span><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghqRiYHHexXHMOqLNKLjoZlZErw8fsr1c6JM9GK-kGuzbW4sYTV2VCC5dksy07GksyJxC4igNp48C7k3EPaQL69kQevTfYreKLdU2PNO3SpxAZMNLbkSOqEQTCVlwBuQba49xBlCCIkNs/s1600/BatteryBox-(1).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5453712092680187234" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghqRiYHHexXHMOqLNKLjoZlZErw8fsr1c6JM9GK-kGuzbW4sYTV2VCC5dksy07GksyJxC4igNp48C7k3EPaQL69kQevTfYreKLdU2PNO3SpxAZMNLbkSOqEQTCVlwBuQba49xBlCCIkNs/s200/BatteryBox-(1).jpg" /></span></a> </p><p><span style="font-size:85%;">Two photo's showing the cover in place prior to final <span id="SPELLING_ERROR_6" class="blsp-spelling-corrected">riveting</span><br /></span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJp4OmNpLyxTfGxzuL8XB_bGlLfOeBkm6t2Su-0HwTLyVPqDuChXRKPRtT7kDu6g_21TdNqAICQ1tgi-AZbHssZgFQcSxMwm4-4fSNhF0dOoD8_UTqOOyWOJ-TmiJlXKJxi4YceoaKH9w/s1600/BatteryBox-(3).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5453712101688203618" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJp4OmNpLyxTfGxzuL8XB_bGlLfOeBkm6t2Su-0HwTLyVPqDuChXRKPRtT7kDu6g_21TdNqAICQ1tgi-AZbHssZgFQcSxMwm4-4fSNhF0dOoD8_UTqOOyWOJ-TmiJlXKJxi4YceoaKH9w/s200/BatteryBox-(3).jpg" /></span></a><span style="font-size:85%;"> </span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJMS4X-MdsI5JZtH4jxzTVis0Vt2FMJoUPS6zKrvXKGdEKy3R6BjImwNQJnz-HDScO9SoYN3a_JbjYSd08guhBXVvFD-1HDAyGF2aliA68X7uDICR0wSzNg3xEZwjNrGgCKLmVb1ny6sw/s1600/BatteryBox-(2).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5453712097318923378" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJMS4X-MdsI5JZtH4jxzTVis0Vt2FMJoUPS6zKrvXKGdEKy3R6BjImwNQJnz-HDScO9SoYN3a_JbjYSd08guhBXVvFD-1HDAyGF2aliA68X7uDICR0wSzNg3xEZwjNrGgCKLmVb1ny6sw/s200/BatteryBox-(2).jpg" /></span></a><br /><span style="font-size:85%;"></span><br /><span style="font-size:85%;">Inside the cover, two pieces of angle have been <span id="SPELLING_ERROR_7" class="blsp-spelling-corrected">riveted</span> in place. These clamp the batteries down preventing the positive/negative terminals from touching the case itself.</span><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2dw07LnXPYBt0sDfkh46SeS0J5A1J6NYqvpwrRorbNZagAbCGxr7EMy7jqwQlMPH87K3qnWO6QGQTGuRYN3rr2tFFgIw8DwMuFAzudn7RmFg3iwhs1BGflQ-ZKJbCCSlIeypD11zrIok/s1600/BatteryBox-(4).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5453712105230100306" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2dw07LnXPYBt0sDfkh46SeS0J5A1J6NYqvpwrRorbNZagAbCGxr7EMy7jqwQlMPH87K3qnWO6QGQTGuRYN3rr2tFFgIw8DwMuFAzudn7RmFg3iwhs1BGflQ-ZKJbCCSlIeypD11zrIok/s200/BatteryBox-(4).jpg" /></span></a><span style="font-family:verdana;"><span style="font-size:85%;"> </span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhOTW1W53l8NUXJ1bRiGiZ2NSc58L1JiEt2alkpv_4-0jCi50xRNPHEweZpUOVEr0HlVPTyjqAY9oalJeQxp1ABM2NFYaEey_heOx4dCtKi0dH_zyKDKFaCTAXK6g8LxYrrRG3FH-djUlM/s1600/BatteryBox-(5).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5453712107848715330" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhOTW1W53l8NUXJ1bRiGiZ2NSc58L1JiEt2alkpv_4-0jCi50xRNPHEweZpUOVEr0HlVPTyjqAY9oalJeQxp1ABM2NFYaEey_heOx4dCtKi0dH_zyKDKFaCTAXK6g8LxYrrRG3FH-djUlM/s200/BatteryBox-(5).jpg" /></span></a><span style="font-size:85%;"> </span></span><br /><span style="font-family:Verdana;font-size:85%;"></span><br /><span style="font-family:Verdana;font-size:85%;">Wiring will pass through the bulkhead and be routed to the instrument panel along the port cockpit side. I have not made up the fixing plates yet but they should be ready to fix in place within the next week. After that the cover and tray will be painted.</span></p><p><span style="font-family:Verdana;font-size:85%;">The next task will be the construction of the parcel shelf. This should be fairly straightforward, I hope. </span></p>Andy Dukehttp://www.blogger.com/profile/09382605630219566798noreply@blogger.com0tag:blogger.com,1999:blog-3930866049742766350.post-24175770963566639552010-02-16T19:41:00.006+00:002010-02-18T07:42:35.221+00:00Priming the fuselage<span style="font-family:verdana;font-size:85%;">As soon as the fuselage is clean corrosion will begin so it is vital that the bare fuselage is painted as soon as possible to protect it from the atmosphere. I completed the cleaning one morning which left the rest of the day, about 7 hours, to prep for, and apply, one coat of primer on the fuselage. In total, the airframe will get three coats of paint:</span><br /><ol><li><span style="font-family:verdana;font-size:85%;">An acid etch primer (green)</span></li><li><span style="font-family:verdana;font-size:85%;">A 2 pack epoxy primer (white)</span></li><li><span style="font-family:verdana;font-size:85%;">A top coat of white two<span id="SPELLING_ERROR_0" class="blsp-spelling-error">-pack</span></span></li></ol><p><span style="font-family:verdana;font-size:85%;">I'm using an <span id="SPELLING_ERROR_1" class="blsp-spelling-error">HVLP</span> (High Volume Low Pressure) spraying system to apply the paints which I'm told is easier for the beginner to get good results with. The system is self contained using a turbine unit to provide air for both the spay gun and a half face mask, essential when working with harmful paints. Details of the equipment can be found at </span><a href="http://www.flexiblesanders.co.uk/proddetail.php?prod=COMBO4STAGE&cat=21"><span style="font-family:verdana;font-size:85%;">http://www.flexiblesanders.co.uk/proddetail.php?prod=COMBO4STAGE&cat=21</span></a><span style="font-family:verdana;font-size:85%;"> although I did upgrade the gun to a gravity feed type at the time of purchase.</span></p><p><span style="font-family:verdana;font-size:85%;">Prior to spraying the fuselage was mounted onto a rotating jig (courtesy of Rob Lees again) which makes the painting process much easier. </span></p><p><span style="font-size:85%;"><span style="font-family:Verdana;"></span></span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhW2NUz9eEVoZ-ObzIfDAfC8eOFvbt6TkKoOPtLrZnbH3WRciWtyan1S-Ue_Pcwq777j11y45pB5o1lArMMJAYqye69JNHWcz2eTCC9Ij1pNi2F6BJHVkOxx-dSJt5j9WMw_kI1j_X-W4k/s1600-h/Fuselage-Jig-(1).jpg"><span style="font-family:Verdana;font-size:85%;"><img style="WIDTH: 134px; HEIGHT: 200px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5438931792020341266" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhW2NUz9eEVoZ-ObzIfDAfC8eOFvbt6TkKoOPtLrZnbH3WRciWtyan1S-Ue_Pcwq777j11y45pB5o1lArMMJAYqye69JNHWcz2eTCC9Ij1pNi2F6BJHVkOxx-dSJt5j9WMw_kI1j_X-W4k/s200/Fuselage-Jig-(1).jpg" /></span></a></p><p><span style="font-family:verdana;font-size:85%;">I started by <span id="SPELLING_ERROR_2" class="blsp-spelling-corrected">spraying</span> all the inside tubes first and gradually working outwards to reduce the chance that I would smudge areas that had already been painted but because of the complexity of a fuselage I did manage to paint myself into a corner on a couple of occasions. I ended up <span id="SPELLING_ERROR_3" class="blsp-spelling-corrected">alternating</span> from front to back to allow painted areas to go off before returning to those tricky areas that had been previously missed.</span></p><p><span style="font-family:verdana;font-size:85%;">Several tips here - get used to your gun, how to change things like the amount of paint sprayed i.e. how wet it goes on as this does vary with the type of paint your using. Practice spraying left and right handed as you're sure to need to change hands at some point. Don't let your gun run dry before recharging with more paint as the paint may dry in the gun nozzle causing problems with delivery. Always clean your gun after use.</span></p><p><span style="font-family:verdana;font-size:85%;">By the end of the day I had a green fuselage and in an ideal world I would apply the next coat (white epoxy) immediately but alas I had run out of time. </span></p><span style="font-family:verdana;font-size:85%;"></span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgU3-UDBZGFOzbcppEN7FmB3TFEP27KwdbISNFI01v1bUYkPkFlZ5CVcNipEgmeHkYHu4sxNffDUgaLJ8ET2snQ11c5HhFHBRlHynZSZpG7RCE09gYxWjiYt1E0t7dZHUfg94sFq1rB6rw/s1600-h/Fuselage-(7).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5438931797297454818" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgU3-UDBZGFOzbcppEN7FmB3TFEP27KwdbISNFI01v1bUYkPkFlZ5CVcNipEgmeHkYHu4sxNffDUgaLJ8ET2snQ11c5HhFHBRlHynZSZpG7RCE09gYxWjiYt1E0t7dZHUfg94sFq1rB6rw/s200/Fuselage-(7).jpg" /></span></a><br /><br /><span style="font-family:verdana;font-size:85%;">The following weekend was spent checking that everything had been sprayed, all those tabs, 'u' <span id="SPELLING_ERROR_4" class="blsp-spelling-corrected">shaped</span> channels, weld clusters etc and where necessary those areas were cleaned ready for retouching. Now because the epoxy hadn't gone on straight away I had two choices for the next stage.</span><br /><ol><li><span style="font-family:verdana;font-size:85%;">lightly scuff the surface to provide a key for the epoxy.</span></li><li><span style="font-family:verdana;font-size:85%;">spray a light flash coat of etch prime on then apply the epoxy.</span></li></ol><p><span style="font-family:verdana;font-size:85%;">I decided on the latter which would ensure a good key over the whole frame and anyway a second light coat wouldn't add much weight at the end of the day. Two hours later I was ready to apply the epoxy using the same techniques as for the etch prime. If I had any black epoxy, it would have been worth mixing a little in so that when it came to spraying the white top coat, I would be spraying onto an off-white colour making it easier to see what I was doing - problem was I didn't have any. </span></p><span style="font-family:verdana;font-size:85%;"></span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmGelbaFj5XsBtW20djTHVxIEh9rQmkRS_aZltUMJxtwf8uXW1K_Wd_gA1o63TU7xR6h1xvJpNlHP534NeUC7X_dsL3wNH2zGEf6ldErrzu5j2MI6f4ywy_IAkY5BdpQPqnwVBZyCdpoI/s1600-h/Fuselage-(5).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 134px; HEIGHT: 200px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5438929511647032818" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmGelbaFj5XsBtW20djTHVxIEh9rQmkRS_aZltUMJxtwf8uXW1K_Wd_gA1o63TU7xR6h1xvJpNlHP534NeUC7X_dsL3wNH2zGEf6ldErrzu5j2MI6f4ywy_IAkY5BdpQPqnwVBZyCdpoI/s200/Fuselage-(5).jpg" /></span></a><span style="font-family:verdana;font-size:85%;"> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDfP4gpApJwzciw4WgXlB0Hpozts3BCK6YyKQRI7pHouOMLgGrzreVbsFlIgIHGGZBNMtOOzP9dwoiBDBcbaaAcZS5b4z8h_1GW-MT9xJnxKtfqKIksdvAccGTlHfkVxeP0Liv44_8Os4/s1600-h/Fuselage-(4).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5438929520183306402" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDfP4gpApJwzciw4WgXlB0Hpozts3BCK6YyKQRI7pHouOMLgGrzreVbsFlIgIHGGZBNMtOOzP9dwoiBDBcbaaAcZS5b4z8h_1GW-MT9xJnxKtfqKIksdvAccGTlHfkVxeP0Liv44_8Os4/s200/Fuselage-(4).jpg" /></span></a></span><br /><p><span style="font-family:verdana;font-size:85%;">The epoxy took about 5 hours to apply with a lot of time spent again on all the tricky corners, tabs, clusters etc. The two photo's show the internal tubes painted white and the final complete airframe which I'm quite happy with. The top coat could just be applied to the cockpit area which will be visible after the fuselage is complete but I may decide to cover the whole frame with top coat as it will give added protection for very little increase in weight. </span></p><p><span style="font-family:verdana;font-size:85%;">In the mean time I have a lot of other bits that are ready for grit blasting and painting up....</p></span>Andy Dukehttp://www.blogger.com/profile/09382605630219566798noreply@blogger.com0tag:blogger.com,1999:blog-3930866049742766350.post-42285070868327979942010-01-28T18:25:00.007+00:002010-01-28T19:29:13.068+00:00Cleaning the fuselage<span style="font-family:verdana;font-size:85%;">Christmas came and went, all the necessary welding work had been completed on the fuselage and so it was time to strip the fuselage frame of all it's paint. I had thought long and hard about how this should be done and had settled on grit blasting rather than paint stripping mainly because paint strippers are messy and toxic (in most cases). I had also decided to do the grit blasting myself rather than transport the fuselage to a professional because (a) I didn't have a means of transport and (b) because of the costs.</span><br /><div><div><span style="font-family:verdana;"></div></span><div><br /><div><span style="font-family:verdana;font-size:85%;">There were a number of prerequisites to the stripping process.</span></div><ol><li><span style="font-family:verdana;font-size:85%;">Create a booth that would take the whole fuselage and keep the rest of the workshop free of dust. This would also serve as the paint spray booth later on.</span></li><br /><li><span style="font-family:verdana;font-size:85%;">Make sure I had the appropriate blasting equipment including safety wear and consumables.</span></li><br /><li><span style="font-family:verdana;font-size:85%;">Get some paint stripper just in case.</span></li><br /><li><span style="font-family:Verdana;font-size:85%;">Arrange for the AD inspection on the strut attachments at an early stage when the weld clusters had been cleaned up.</span></li></ol><p><span style="font-family:verdana;font-size:85%;">The booth was made from white tarpaulin sheet hung from the roof beams with the lights inside the booth. The dimensions were about 20 x 10 feet giving enough room to work around the fuselage. I also have a small extractor fan used to keep the dust down. </span><br /></p><br /><p><span style="font-family:verdana;font-size:85%;">I bought a cheep hopper (</span><a href="http://www.northerntooluk.com/sandblasting/sandblasting-accessories/portable-shot-blasting-kit_146993E.html"><span style="font-family:verdana;font-size:85%;">h</span></a><a href="http://www.northerntooluk.com/sandblasting/sandblasting-accessories/portable-shot-blasting-kit_146993E.html"><span style="font-family:verdana;font-size:85%;">ttp://www.northerntooluk.com/sandblasting/sandblasting-accessories/portable-shot-blasting-kit_146993E.html</span></a><span style="font-family:verdana;font-size:85%;">) which holds a 25 Kg bag of grit/bead and utilises my compressor running at about 115 psi. In practice, this would last for about 30-40 minutes before having to be topped up. I also purchased a hood with spare lenses, gauntlets and disposable overalls to wear during the blasting.</span><br /></p><br /><p><span style="font-family:verdana;font-size:85%;">I anticipated the blasting would take three days to complete followed by a day to paint the fuselage but as ever it took longer for several reasons. After three days I had completed the initial blasting but there was a lot of paint that just wouldn't come off mainly around the cockpit area.</span><br /></p><br /><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjyynNnNN7yK5cVjSnJ50Hh_2hdFS9yAnzVhJ9qGUEGGizFZuSZrvkU1vvTQWoi3nSkthOMwrYZzoco5pfkToaKh9fYkdnykRWTKvWSvREuNTO2y_o6LS-3G0mxnJQcS2SRcC41_XoZWH4/s1600-h/Fuselage-(2).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 150px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5431865336398999474" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjyynNnNN7yK5cVjSnJ50Hh_2hdFS9yAnzVhJ9qGUEGGizFZuSZrvkU1vvTQWoi3nSkthOMwrYZzoco5pfkToaKh9fYkdnykRWTKvWSvREuNTO2y_o6LS-3G0mxnJQcS2SRcC41_XoZWH4/s200/Fuselage-(2).jpg" /></span></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjthZ4_NvEEmjfNguXhNTa4xmEuTw5tMvWFZaFIvdxicFWObH-IzXF1lZzUvmPZ7QaEw5_1KgByh9Vp4Np9BqZkWdjXpBndupkChuo5IJsvhAgRCtZ-Cs_GNEb0PYeVJB8qlV-v4B5mnQU/s1600-h/Blasting-(1).jpg"><img style="WIDTH: 200px; HEIGHT: 150px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5431874610150833058" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjthZ4_NvEEmjfNguXhNTa4xmEuTw5tMvWFZaFIvdxicFWObH-IzXF1lZzUvmPZ7QaEw5_1KgByh9Vp4Np9BqZkWdjXpBndupkChuo5IJsvhAgRCtZ-Cs_GNEb0PYeVJB8qlV-v4B5mnQU/s200/Blasting-(1).jpg" /></a></p><p><span style="font-family:verdana;font-size:85%;">There was a mixture of paints, what looked like powder coating and some rubberised coating which I decided might come off better if I applied paint stripper. Another day was spent applying the stripper. The paint stripper used was SV-35/PMA formulated specifically for aviation paints (</span><a href="http://www.paint-stripper.co.uk/removall_paint_stripper_aviation.htm"><span style="font-family:verdana;font-size:85%;">http://www.paint-stripper.co.uk/removall_paint_stripper_aviation.htm</span></a><span style="font-family:verdana;font-size:85%;">) and non-toxic. I left the stripper overnight to be cleaned off the next day. The results looked pretty good. I can recomend this product as it's easy to work with, strips the paint quickly (I was working in neart freezing conditions over winter so it should work very quickly in the summer months) and is easy to dispose of afterwards.</span></p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioCLqQRwWWzsTcNpAf3pyDtcGNmLVAA19_Ekipre2Ber31vIATQ9kDCFdAbo8YbcKjvcBgPx3npzqD2lwk9GikPatxkcDAE-mse6s1-svixwjhhqJsgBLpxKW4fWL8zIgMZqR4UsRYNxY/s1600-h/Paint-Stripper-(1).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5431867128575537618" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioCLqQRwWWzsTcNpAf3pyDtcGNmLVAA19_Ekipre2Ber31vIATQ9kDCFdAbo8YbcKjvcBgPx3npzqD2lwk9GikPatxkcDAE-mse6s1-svixwjhhqJsgBLpxKW4fWL8zIgMZqR4UsRYNxY/s200/Paint-Stripper-(1).jpg" /></span></a><span style="font-family:verdana;font-size:85%;"> </span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqDDlje6IhQMa-7f5IK9Yz95i6GcoxyOTG7-oFePxFt-9A_PQ9EASn08-P1p6FOUdj27jeawSh9vC2wEq-pGkj90LMmLZu-eEOGFrICF8HYNN6gi0rK_7mMB397oPjLSxymSCClTJko04/s1600-h/Paint-Stripper-(2).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5431867129562484866" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqDDlje6IhQMa-7f5IK9Yz95i6GcoxyOTG7-oFePxFt-9A_PQ9EASn08-P1p6FOUdj27jeawSh9vC2wEq-pGkj90LMmLZu-eEOGFrICF8HYNN6gi0rK_7mMB397oPjLSxymSCClTJko04/s200/Paint-Stripper-(2).jpg" /></span></a></p><div><span style="font-family:verdana;font-size:85%;">The approved method for removing the crud is by pressure washing with water which I don't have the equipment to do so instead it was brushed off with water, a messy and time consuming job. I then had to bead blast the whole fuselage again to clean up the remaining paint. </span></div><br /><div><span style="font-family:verdana;font-size:85%;">There were still odd spots of paint which hadn't been removed so another day was spent getting these off by using a craft knife blade followed by further bead blasting.<br /></span></div><br /><div><span style="font-family:verdana;font-size:85%;">The finished product was cleaned with an air hose and tack cloths prior to painting.<br /></div></span><br /><p><span style="font-family:verdana;font-size:85%;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8D3e49eV7SwzJZ7iYkgz0MDhw3-ZJe2WqJq1Yv3YILe2Bx03hbQB-y0op2wZm-MLyt075WOM1rKSOzsyM-JTFTdlwTZAUhpOrOcahMfohMfivcXbtukeeG6vztfPGfapYrisWzMlwrvw/s1600-h/Fuselage-(3).jpg"><img style="WIDTH: 200px; HEIGHT: 150px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5431869809886375154" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8D3e49eV7SwzJZ7iYkgz0MDhw3-ZJe2WqJq1Yv3YILe2Bx03hbQB-y0op2wZm-MLyt075WOM1rKSOzsyM-JTFTdlwTZAUhpOrOcahMfohMfivcXbtukeeG6vztfPGfapYrisWzMlwrvw/s200/Fuselage-(3).jpg" /></a></span></p><p><span style="font-family:Verdana;font-size:85%;">In all the process took about 10 days spread over 4 weeks, but I did loose a week because the weather over here was so bad I couldn't get to the workshop. In hindsight I should have spent more time paint stripping and left the bead blasting just for the final finish but that's what this blog is about, helping you save time through my experiences. I think a realistic timetable for the job would have been 2 days to paint strip, 1 day to clean and 3 days to blast, still a lot of work but very satisfying once completed.</span></p><p><span style="font-family:Verdana;font-size:85%;">Next time, priming the fuselage.</span></p></div></div>Andy Dukehttp://www.blogger.com/profile/09382605630219566798noreply@blogger.com0tag:blogger.com,1999:blog-3930866049742766350.post-37020256613275891822010-01-26T20:21:00.007+00:002010-01-28T18:25:09.485+00:00Welding Work<span style="font-family:verdana;font-size:85%;">During December I begun the preparation of the fuselage for it's eventual bead blasting and painting. There was no repair work necessary as the aircraft has never been crashed and there is no evidence of major corrosion but there are a number of other jobs that need to be completed.<br /></span><div><div><br /><div><span style="font-family:verdana;font-size:85%;">The job list included: </span></div><ol><li><span style="font-family:verdana;font-size:85%;">Adding structural harness attachment points.</span></li><br /><li><span style="font-family:verdana;font-size:85%;">Welding on additional tabs to support the baggage sling, 'D' windows, hat shelf, floor boards and skylight.<br /></span></li><li><span style="font-family:verdana;font-size:85%;">Welding up and <span id="SPELLING_ERROR_0" class="blsp-spelling-corrected">re drill</span> the rear horizontal stabiliser mounting holes (to be <span id="SPELLING_ERROR_1" class="blsp-spelling-corrected">re drilled</span>).<br /></span></li><li><span style="font-family:verdana;font-size:85%;">Have my inspector sign of AD.2008-09-18 (Wing strut attachment bracket).</span></li></ol><p><span style="font-family:verdana;font-size:85%;">The plan was that if these jobs could be completed by Christmas, then I would grit blast and paint the fuselage in the period between Christmas and the New Year. Of course things don't always go as planned, but more of that later.</span></p><p><span style="font-family:verdana;font-size:85%;">The first problem <span id="SPELLING_ERROR_2" class="blsp-spelling-corrected">encountered</span> was that the <span id="SPELLING_ERROR_3" class="blsp-spelling-corrected">harness</span> brackets that had been made (</span><a href="http://gbrih.blogspot.com/2009/11/harness-brackets.html"><span style="font-family:verdana;font-size:85%;">http://gbrih.blogspot.com/2009/11/harness-brackets.html</span></a><span style="font-family:verdana;font-size:85%;">) were flawed, the bolt couldn't be fitted because the fabric would interfere, so I <span id="SPELLING_ERROR_4" class="blsp-spelling-corrected">had</span> to make new ones to fit (see below). They were manufactured in the same way with the same spec material but now weld at an angle to give better clearance.<br /></span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1FinFx12ITw3jTcSvY0ZA8r5hENUB2mh-z30itKi-DfntVl6i7T0TjGKrRJ289EdDA7GaeuJaWozp949wJmDWqp7zmNbIPvdv0wdfbFr4I-HFvoGUwedsTZIe2VfMtj6GqP844W0XLCc/s1600-h/Harness-(3).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 150px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5431151776178691842" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1FinFx12ITw3jTcSvY0ZA8r5hENUB2mh-z30itKi-DfntVl6i7T0TjGKrRJ289EdDA7GaeuJaWozp949wJmDWqp7zmNbIPvdv0wdfbFr4I-HFvoGUwedsTZIe2VfMtj6GqP844W0XLCc/s200/Harness-(3).jpg" /></span></a><span style="font-family:verdana;font-size:85%;"> </span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMNbxUkWzTW5lvDVAh8guH3SJdMygNbOFx1abJG_CPh0r9v0cQc23sZG0SWaBsk7dhI-EbrqzMD1I1OuhyphenhyphenuvINTmKwF9hy-cckYrJNaM5H1P_oGRRmmeqwQ-6Ov7jJC42SufrNICZzXLc/s1600-h/Harness-(4).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 150px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5431151783111629522" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMNbxUkWzTW5lvDVAh8guH3SJdMygNbOFx1abJG_CPh0r9v0cQc23sZG0SWaBsk7dhI-EbrqzMD1I1OuhyphenhyphenuvINTmKwF9hy-cckYrJNaM5H1P_oGRRmmeqwQ-6Ov7jJC42SufrNICZzXLc/s200/Harness-(4).jpg" /></span></a><span style="font-family:verdana;font-size:85%;"> </span></p><p><span style="font-family:verdana;font-size:85%;">My friend David made four post supports from 4130 rod with an internal M6 thread. These were welded to the fuselage to provide additional support for the skylight.</span></p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIROpaHZ8ddFLq3WDJGxo_H3f7DR6RPYryQnp3iM7zgUOL6U_Stt6DYnhUI6zwJ0_X1isxTpUG976BZ-XvtKNiico9kpSz9lSoyFfWp-5YDTA1SHADQn-fGj51ErBMOezdmm45E_EbgqA/s1600-h/Skylight-(9).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 150px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5431153863493980050" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIROpaHZ8ddFLq3WDJGxo_H3f7DR6RPYryQnp3iM7zgUOL6U_Stt6DYnhUI6zwJ0_X1isxTpUG976BZ-XvtKNiico9kpSz9lSoyFfWp-5YDTA1SHADQn-fGj51ErBMOezdmm45E_EbgqA/s200/Skylight-(9).jpg" /></span></a><br /><p><span style="font-family:verdana;font-size:85%;">The additional tabs were all welded on over a couple of evenings and I begun to plan the cleaning and painting of the fuselage frame. </span></p><p><span style="font-family:verdana;font-size:85%;">The AD inspection was scheduled to be done once the fuselage had been bead blasted as this was purely a one off inspection for corrosion or cracks around the strut attachment fittings and it would mean I wouldn't have to remove paint at a later date.</span></p><p><span style="font-family:Verdana;font-size:85%;">I'll discuss stripping and repainting the fuselage in the next posting soon.</span></p></div></div>Andy Dukehttp://www.blogger.com/profile/09382605630219566798noreply@blogger.com0tag:blogger.com,1999:blog-3930866049742766350.post-65313734569159210662009-11-08T14:53:00.002+00:002009-11-08T15:05:11.049+00:00Harness Brackets<span style="font-family:verdana;font-size:85%;"> When I bought IH back in 1998, the aircraft was fitted with a 4-point harness where the shoulder straps were attached to the cross tube that supports the top a the seat sling. This was totally unacceptable as in a crash this can lead to compression of the spine and severe back injuries. Later I moved the attachment position to one of the top cross members further back in the fuselage using a U-bracket around the cross tube. This was better but not perfect, so now I'm taking the oppotunity to weld some permanent brackets into the airframe.</span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;">Two brackets were cut from .090" 4130 steel plate and drilled to take an AN4 bolt. After welding, the holes will be reamed out to size.</span><br /><br /><span style="font-family:verdana;font-size:85%;">Port and Starboard fittings</span><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRDapNVKkT49x05hpwbG43ao9j96pOEqxM8VwHPVYvfjkOdMWzJLu-zFvcZso3dbRbh3BxULxrK-4e2c0DEu6fTvFKKW5HnfW2a78FoepRyem9up0O8FqyB6Z_W-YuBApAd_js6v31pQs/s1600-h/Harness-(1).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5401746421824649314" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRDapNVKkT49x05hpwbG43ao9j96pOEqxM8VwHPVYvfjkOdMWzJLu-zFvcZso3dbRbh3BxULxrK-4e2c0DEu6fTvFKKW5HnfW2a78FoepRyem9up0O8FqyB6Z_W-YuBApAd_js6v31pQs/s200/Harness-(1).jpg" /></span></a><span style="font-family:verdana;font-size:85%;"> </span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEia0yb55ORbTlfxSnCzWOCZStxEzMDfCBUepAeE0Pc2VU9V2SAaHEuiuVB1oWBc98pNh937LOoZZubnzOrudUE-TJ_d9bTIe99l2GprRwGn-qImNI0YTA4P34GvDgOZyzYSUYnlmQw3ISY/s1600-h/Harness-(2).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5401746420754828578" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEia0yb55ORbTlfxSnCzWOCZStxEzMDfCBUepAeE0Pc2VU9V2SAaHEuiuVB1oWBc98pNh937LOoZZubnzOrudUE-TJ_d9bTIe99l2GprRwGn-qImNI0YTA4P34GvDgOZyzYSUYnlmQw3ISY/s200/Harness-(2).jpg" /></span></a><span style="font-family:verdana;font-size:85%;"><br /><br /></span><div></div>Andy Dukehttp://www.blogger.com/profile/09382605630219566798noreply@blogger.com0tag:blogger.com,1999:blog-3930866049742766350.post-73351821720457335352009-11-07T15:45:00.005+00:002009-11-07T16:33:02.421+00:00Refurbishing the Fuel Tanks<span style="font-family:verdana;font-size:85%;">IH has three fuel tanks, one in each wing plus the header tank in the nose, and these need some refurbishment and pressure testing before they are refitted. For now I only need to have the nose tank sorted but I'll work on all the tanks as they will all need the same treatment. </span><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgf1cWcW3Gp-tATuvYkR7iZzIu1C6ZseEaWtA5UezdT6b5DP5BLQFaRqR8wTm4div7T1B-OsNAugAzvaaNIE4qO_UcxXimjk6FACDi5Gxs764gN5-SeXFgTKaAapxZmS0-d0RQb793Zdp8/s1600-h/Fuel-Tank-(2).jpg"><span style="font-family:verdana;font-size:85%;"></span></a><br /><span style="font-family:verdana;font-size:85%;">Firstly, I bought new fittings for each tank to enable me to fit all new AN fittings throughout the aircraft. The tanks still have their original heavy fittings and also showed some signs of mistreatment around the filler where the pipe has been used unsupported when fueling. So the plan is to weld in new fittings and filler necks and reinforce the area around the filler necks.</span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;">The tanks were sent away to a local CAA welding company; the tanks were labelled with the fitting part numbers next to the appropriate existing fittings. The results of the welding are shown below.<br /></span><br /><span style="font-family:verdana;font-size:85%;">Main Tank</span><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrOceLF7Obey1bMcnPCuFC7KOPhzPKm2kA3ZsrpP0HZEdCVzh5lF_HCwTUH_Ms-EHnhTVW64e8V6yr0obBEr63wBbWAA9d0xmY0_dyTo9-38Uthfk8_lRmCBHW_PwrL4fvBuiXFbqPzZc/s1600-h/Fuel-Tank-(3).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5401391690910622354" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrOceLF7Obey1bMcnPCuFC7KOPhzPKm2kA3ZsrpP0HZEdCVzh5lF_HCwTUH_Ms-EHnhTVW64e8V6yr0obBEr63wBbWAA9d0xmY0_dyTo9-38Uthfk8_lRmCBHW_PwrL4fvBuiXFbqPzZc/s200/Fuel-Tank-(3).jpg" /></span></a><span style="font-family:verdana;font-size:85%;"> </span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZAqmNct4YChowa-RsynJWGIFC63HCUgRg4dVd-sB7nsDUS4x8xbEMpfqr4b3XDKvAYUUT99x8cDN1VAt771Feb-7_7AF5Mo1RtpEgLemg-MR_hSL6WEsIitBSnSSEhUOka7a34mv-qS0/s1600-h/Fuel-Tank-(4).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5401391689586893378" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZAqmNct4YChowa-RsynJWGIFC63HCUgRg4dVd-sB7nsDUS4x8xbEMpfqr4b3XDKvAYUUT99x8cDN1VAt771Feb-7_7AF5Mo1RtpEgLemg-MR_hSL6WEsIitBSnSSEhUOka7a34mv-qS0/s200/Fuel-Tank-(4).jpg" /></span></a><span style="font-family:verdana;font-size:85%;"> </span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgf1cWcW3Gp-tATuvYkR7iZzIu1C6ZseEaWtA5UezdT6b5DP5BLQFaRqR8wTm4div7T1B-OsNAugAzvaaNIE4qO_UcxXimjk6FACDi5Gxs764gN5-SeXFgTKaAapxZmS0-d0RQb793Zdp8/s1600-h/Fuel-Tank-(2).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5401391692731416978" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgf1cWcW3Gp-tATuvYkR7iZzIu1C6ZseEaWtA5UezdT6b5DP5BLQFaRqR8wTm4div7T1B-OsNAugAzvaaNIE4qO_UcxXimjk6FACDi5Gxs764gN5-SeXFgTKaAapxZmS0-d0RQb793Zdp8/s200/Fuel-Tank-(2).jpg" /></span></a><br /><span style="font-family:verdana;font-size:85%;">Wing Tank<br /></span><div><span style="font-family:verdana;font-size:85%;"></span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgp8fe8-YiHb8FNk8PQYYg7F388zPjq7L0zx1vp9GRmwvz25fc7nRPyQRJiRZt9x01d5B6ZFs6sgvxLE-SfjlzZnm7T8yQvF3IGsA4lSMMgUvHLOPvICW7jN85Cj3kkUXgwEv2pE0aPfVw/s1600-h/Fuel-Tank-(9).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5401390727611174642" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgp8fe8-YiHb8FNk8PQYYg7F388zPjq7L0zx1vp9GRmwvz25fc7nRPyQRJiRZt9x01d5B6ZFs6sgvxLE-SfjlzZnm7T8yQvF3IGsA4lSMMgUvHLOPvICW7jN85Cj3kkUXgwEv2pE0aPfVw/s200/Fuel-Tank-(9).jpg" /></span></a><span style="font-family:verdana;font-size:85%;"> </span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwNtCR5A3bDgvqOM7vB0L6b-VVzrTbN3hLuOpIyfOvMtNg4HN59FSf0wG7ojVk4morjvQEeERQoHDk547mRKlXyNR5B9bm47BJAvkGnJcMWCGk37_ahz21Dpn_-HIMvcg3RsjxQqP_4wk/s1600-h/Fuel-Tank-(10).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5401390721462105474" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwNtCR5A3bDgvqOM7vB0L6b-VVzrTbN3hLuOpIyfOvMtNg4HN59FSf0wG7ojVk4morjvQEeERQoHDk547mRKlXyNR5B9bm47BJAvkGnJcMWCGk37_ahz21Dpn_-HIMvcg3RsjxQqP_4wk/s200/Fuel-Tank-(10).jpg" /></span></a><span style="font-family:verdana;font-size:85%;"> </span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiuXY_YZnvbd_aYl_eIyhQImbPFuN5gc0pI0cT-uuPMMr0YUB6mZJO-Q9rT-9f0UrW9uk1YWydSqvjO90biiU_IMV1bFu8RakUO_d0dPzjDoSP0OOJAWxLlohKION1LXRPX9yRcbiVCbK0/s1600-h/Fuel-Tank-(7).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5401390731682362402" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiuXY_YZnvbd_aYl_eIyhQImbPFuN5gc0pI0cT-uuPMMr0YUB6mZJO-Q9rT-9f0UrW9uk1YWydSqvjO90biiU_IMV1bFu8RakUO_d0dPzjDoSP0OOJAWxLlohKION1LXRPX9yRcbiVCbK0/s200/Fuel-Tank-(7).jpg" /></span></a></div><div><span style="font-family:verdana;font-size:85%;"></span></div><div><span style="font-family:verdana;font-size:85%;">The tanks were also pressure tested by the welding company and all pin holes and cracks welded, so I now have a good set of tanks.</span></div><div><span style="font-family:verdana;font-size:85%;"></span></div><div><span style="font-family:verdana;font-size:85%;">The paint was then stripped from the outside of the tanks using proprietory paint stripper and scotchbright to produce tanks ready for priming.<br /></span></div><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh34pN7ZBmMplV74t7NYCLR6JZG8YArlu4SaKKf4KCE73Clf3lBnqRcn9xWTCwEaDMfHfB0tfT94hF2RQz6ba0v-iIda9Ctukj6SPtSmZAYw8_gQrsV4l1tdIdkiicEHU6zY-R-YpLbZIo/s1600-h/Fuel-Tank-(5).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5401391683399704322" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh34pN7ZBmMplV74t7NYCLR6JZG8YArlu4SaKKf4KCE73Clf3lBnqRcn9xWTCwEaDMfHfB0tfT94hF2RQz6ba0v-iIda9Ctukj6SPtSmZAYw8_gQrsV4l1tdIdkiicEHU6zY-R-YpLbZIo/s200/Fuel-Tank-(5).jpg" /></span></a><span style="font-family:verdana;font-size:85%;"> </span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi76adHo7J7ObDaTS8PPWKA6K1YQm3QHropszFyygZPZSRVIFEpXGKk-WVyPzzlE9nRug3Uq1yuRI5oHgRWA9W0rgpxwUN94xJr94YyLGDaXDeUIaH9_lwhQ6Khizb71XpmJtCf9pU4x0Q/s1600-h/Fuel-Tank-(8).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5401390730282618242" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi76adHo7J7ObDaTS8PPWKA6K1YQm3QHropszFyygZPZSRVIFEpXGKk-WVyPzzlE9nRug3Uq1yuRI5oHgRWA9W0rgpxwUN94xJr94YyLGDaXDeUIaH9_lwhQ6Khizb71XpmJtCf9pU4x0Q/s200/Fuel-Tank-(8).jpg" /></span></a></div><div><span style="font-family:verdana;font-size:85%;"></span></div><div><span style="font-family:verdana;font-size:85%;">The tanks were first painted with an acid etch primer and then painted in a white epoxy primer. The nose tank will eventually get a white top coat as well as this is visible within the cockpit. Note that when painting the fitting holes were blanked off to prevent paint getting either inside the tanks or into the fittings threads.<br /><br />The finished epoxy primed tanks.</span></div><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhfH3lqpxH9e07VpsnpAfN7i6CJVUigqE3qwJ1-5YlYiEMJmMxmHjiUC46Bag89wjB7ywNIVuteIO4eKJa8k2RoZkeW4Qwdr3zrdLXEHvyghNzlOK_xH9auJBgeEPMFi00alejy9Qel3nA/s1600-h/Fuel-Tank-(6).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5401391685620566450" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhfH3lqpxH9e07VpsnpAfN7i6CJVUigqE3qwJ1-5YlYiEMJmMxmHjiUC46Bag89wjB7ywNIVuteIO4eKJa8k2RoZkeW4Qwdr3zrdLXEHvyghNzlOK_xH9auJBgeEPMFi00alejy9Qel3nA/s200/Fuel-Tank-(6).jpg" /></span></a><span style="font-family:verdana;font-size:85%;"> </span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFxLGHRCwle0hbGmgA6aD7HXfqmU9w1Xz3q9u10bAdfnzZP0kdrV9qOmwVH6vZW-Jmw-RBIM_0MXNzmOQGig4VHZ6LLIEs3UKk2SZusG3AaQJ9XMAXhXADXSdfmbz5y4JZluVlGJ56dm4/s1600-h/Fuel-Tank-(11).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5401390719130682050" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFxLGHRCwle0hbGmgA6aD7HXfqmU9w1Xz3q9u10bAdfnzZP0kdrV9qOmwVH6vZW-Jmw-RBIM_0MXNzmOQGig4VHZ6LLIEs3UKk2SZusG3AaQJ9XMAXhXADXSdfmbz5y4JZluVlGJ56dm4/s200/Fuel-Tank-(11).jpg" /></span></a><span style="font-family:verdana;font-size:85%;"><br /></span><div></div></div>Andy Dukehttp://www.blogger.com/profile/09382605630219566798noreply@blogger.com0tag:blogger.com,1999:blog-3930866049742766350.post-73941993299540458432009-11-07T14:27:00.002+00:002009-11-07T15:42:23.231+00:00More on Floorboards<span style="font-family:verdana;font-size:85%;"> It's been a while since I made the mock up of the floorboards but at last I made the effort to get some qualaity birch plywood for the final product. Using the mocked up floorboards with I marked out the outline of the floorboards onto the birch ply paying attention so that there were no blemishes in the birch.</span><br /><span style="font-family:verdana;font-size:85%;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi07OhklJQ3b3_J6H65OMV5XscefYrdRru9grT-BVOJuDYvYr-Pj6bT89n4CP_nT9HrgH6cj0aZOZXRdduA7RdN9JZv-WIfHoLqRGAPc1rjtRkMeSAoEA3K0XF18hyLhr4pdNhkOUHGDVM/s1600-h/Floorboards-(6).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5401370535662569490" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi07OhklJQ3b3_J6H65OMV5XscefYrdRru9grT-BVOJuDYvYr-Pj6bT89n4CP_nT9HrgH6cj0aZOZXRdduA7RdN9JZv-WIfHoLqRGAPc1rjtRkMeSAoEA3K0XF18hyLhr4pdNhkOUHGDVM/s200/Floorboards-(6).jpg" /></span></a> </span><br /><span style="font-family:verdana;font-size:85%;">There were a couple of differences between the mock up and the final boards (go to </span><a href="http://gbrih.blogspot.com/2008/01/new-interior-floorboards.html"><span style="font-family:verdana;font-size:85%;">http://gbrih.blogspot.com/2008/01/new-interior-floorboards.html</span></a><span style="font-family:verdana;font-size:85%;"> to see details of the mocked up floorboards) to incorporate improvements, mainly around the cut out for the brake pedels. </span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;">Cutting was done with a band saw, fly cutter and fret saw to get the required shapes; one useful tip here is to score the underside of the ply along the proposed cut with a knife, this prevents the underside from ripping when sawn giving a clean edge to the ply. </span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:Verdana;font-size:85%;">The boards were drilled to take the self tapping screws that will fix them to the fuselage (tabs on the fuselage will have tinnerman nuts fitted).</span><br /><span style="font-family:Verdana;font-size:85%;"> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjYDmVswsf8XpMm2uep0YfLUlHOolB6Igq-Ks5LeOu0Bhm0q2_iMtwF_GR21xF_3li1hkCOmRv_sxWaq4n1dLncfZ0l9dK2_3g_agyLWgplBRrhnq5zSuI6zDk_Wg3LEGuA7qdlLMQXQlQ/s1600-h/Floorboards-(7).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5401370531539940258" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjYDmVswsf8XpMm2uep0YfLUlHOolB6Igq-Ks5LeOu0Bhm0q2_iMtwF_GR21xF_3li1hkCOmRv_sxWaq4n1dLncfZ0l9dK2_3g_agyLWgplBRrhnq5zSuI6zDk_Wg3LEGuA7qdlLMQXQlQ/s200/Floorboards-(7).jpg" /></span></a></span><br /><span style="font-family:verdana;font-size:85%;">The boards were then sanded and given a brush coat of varnish. Once this had gone off the varnish was sanded lightly to de-nib it and thre more layers of varnish were sprayed on. For spraying the varnish was thinned down with MEK in the ration 1 part varnish to 4 parts MEK.<br /></span><br /><span style="font-family:verdana;font-size:85%;">Finally the bulkhead under the seats was cut and fitted. This is screwed into the crossmember under the front of the seat sling and will drop into a slot formed by two quater round strips of wood glued to the rear part of the floorboards. the battery box, which I have yet to make, will be positioned in the middle of the floorforward of the bulkhead.<br /></span><span style="font-family:verdana;font-size:85%;"></span><span style="font-family:verdana;font-size:85%;"> </span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj57XdH-B6SNklvN1uQ9rsF8HecTadx9v1pW3DCx-kyBEQmwJ-T1kOOBCo6vAua9zGqr3D6fCVtKMBQ0MUkR3HSY-FLZJ5CTYDv1bsOKPCasK2pcykwZf6LIaqNSmylH8WNvwUBdL32nsA/s1600-h/Floorboards-(8).jpg"><span style="font-family:verdana;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5401370525499101010" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj57XdH-B6SNklvN1uQ9rsF8HecTadx9v1pW3DCx-kyBEQmwJ-T1kOOBCo6vAua9zGqr3D6fCVtKMBQ0MUkR3HSY-FLZJ5CTYDv1bsOKPCasK2pcykwZf6LIaqNSmylH8WNvwUBdL32nsA/s200/Floorboards-(8).jpg" /></span></a><span style="font-family:verdana;font-size:85%;"> </span><br /><span style="font-family:verdana;font-size:85%;">I have still got to get a couple of extra tabas welded to the fuselage frame to provide additional anchor points for the floorboards but this should be done within the next couople of weeks as I write.<br /><br /><br /><br /></span><span style="font-family:verdana;font-size:85%;"></span>Andy Dukehttp://www.blogger.com/profile/09382605630219566798noreply@blogger.com0tag:blogger.com,1999:blog-3930866049742766350.post-75114899061785980032009-08-16T18:46:00.006+01:002009-08-16T20:40:54.788+01:00Making new rear d-windows<span style="font-family:trebuchet ms;font-size:85%;"> By June it was clear that there were a number of tasks that needed doing before I could go ahead and get all the welding done on the fuselage. One of these taks was to build new rear D-windows. This was important as a tab would have to be welded that would fix the window to the fuselage and tie the window into the stringers along the fuselage. </span><br /><span style="font-family:trebuchet ms;font-size:85%;"></span><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjk7V5zoXM74G2Id3Zo2flZE7Q0PuV5uwU1pk-qBEVEgS-fpYWZ5pqsGLKU4tYp2K9DyGrK0yK1XcUyro5uJQFybw1fPm15FShvETOJ2VV4db8PxG6p-P3Uivo6PeBeSJvozQmugXdUVrk/s1600-h/D-Window-(1).jpg"><span style="font-family:trebuchet ms;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5370626766313736866" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjk7V5zoXM74G2Id3Zo2flZE7Q0PuV5uwU1pk-qBEVEgS-fpYWZ5pqsGLKU4tYp2K9DyGrK0yK1XcUyro5uJQFybw1fPm15FShvETOJ2VV4db8PxG6p-P3Uivo6PeBeSJvozQmugXdUVrk/s200/D-Window-(1).jpg" /></span></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjk7V5zoXM74G2Id3Zo2flZE7Q0PuV5uwU1pk-qBEVEgS-fpYWZ5pqsGLKU4tYp2K9DyGrK0yK1XcUyro5uJQFybw1fPm15FShvETOJ2VV4db8PxG6p-P3Uivo6PeBeSJvozQmugXdUVrk/s1600-h/D-Window-(1).jpg"></a><br /><span style="font-family:trebuchet ms;font-size:85%;">The old D-windows looked very similar to the Harer STC windows but the position was wrong, they were fixed too high so that the top of the window was higher than the door frame and the line of the door window was not carried through to the rear window. The old window frame was also very heavy so I also have the oppotunity to make thing lighter again.</span><br /><span style="font-family:trebuchet ms;font-size:85%;"></span><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4QbColACMdO7dym8OeVDBjgvoh8dZpNs_asV5eyosqAxYSRwhj2k7ujq76G2D1QfjuSUoJ7lkmcdvL5vIs37YYLK2Qbc91TRVPgq-3QhGNssrSwJyEGAsd01Bnty0LEChwEtmSBLigG0/s1600-h/D-Window-(2).jpg"><span style="font-family:trebuchet ms;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5370626770073757202" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4QbColACMdO7dym8OeVDBjgvoh8dZpNs_asV5eyosqAxYSRwhj2k7ujq76G2D1QfjuSUoJ7lkmcdvL5vIs37YYLK2Qbc91TRVPgq-3QhGNssrSwJyEGAsd01Bnty0LEChwEtmSBLigG0/s200/D-Window-(2).jpg" /></span></a><span style="font-family:trebuchet ms;font-size:85%;"> </span><br /><span style="font-family:trebuchet ms;font-size:85%;">I have no specific plans for constructing a set of windows so I based the shape of the new windows on those in the Harer STC but slightly smaller. The design was schetched out full size on stiff paper which was then taped to my work surface. The main difficulty was getting the correct angle between the rear door frame (to which the window will be attached) and the line of the door window so that the top of the two windows will line up correctly. I cannot guarantee that this is the same on all aircraft but it worked out to be 100 degrees for me.</span><br /><span style="font-family:trebuchet ms;font-size:85%;"></span><br /><span style="font-family:trebuchet ms;font-size:85%;">The frame is made in two parts, the main part holds the window glazing and is attached to the door frame with machines screws and nuts, and the fusalage tubing with self tapping screws. A separate outer frame is then used to trap the glazing in.</span><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBjmN7M0CH8BhOqxH_1lDxJVHS_tsNGFh6PyJfRrV7NQfxAI4WIkzCvTk6GHdEVqycy1EugGFV8As-PVtLyUKwE1xiJMk9e91vqt-n8Rv3AsydXHcaL8PrEB2ecvqHnysvI1B_VrrPtUI/s1600-h/D-Window-(4).jpg"><span style="font-family:trebuchet ms;font-size:85%;"><img style="WIDTH: 134px; HEIGHT: 200px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5370626785968888914" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBjmN7M0CH8BhOqxH_1lDxJVHS_tsNGFh6PyJfRrV7NQfxAI4WIkzCvTk6GHdEVqycy1EugGFV8As-PVtLyUKwE1xiJMk9e91vqt-n8Rv3AsydXHcaL8PrEB2ecvqHnysvI1B_VrrPtUI/s200/D-Window-(4).jpg" /></span></a><span style="font-family:trebuchet ms;font-size:85%;"> </span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjVN6wbUImgKh32evqBY-K8U5kmQjtW_ABwunUJUMtZfyIldc3b6A0eE8pbYJb40UjvZcaUipzSBtKGPwYkd5IWuDGouAA-2KFdnJMOXbxqnghXMDvxKg6Yly1EXS16EDMpEAIPeJxBFvo/s1600-h/D-Window-(10).jpg"><span style="font-family:trebuchet ms;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5370627221809580002" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjVN6wbUImgKh32evqBY-K8U5kmQjtW_ABwunUJUMtZfyIldc3b6A0eE8pbYJb40UjvZcaUipzSBtKGPwYkd5IWuDGouAA-2KFdnJMOXbxqnghXMDvxKg6Yly1EXS16EDMpEAIPeJxBFvo/s200/D-Window-(10).jpg" /></span></a><span style="font-family:trebuchet ms;font-size:85%;"> </span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgwBHu8AAOgZu3bW0zmJXNCxFVIPFka0A1hqxVXtCSf6KZJOzKUFYM4a-k1TIeYRe0LCDHeEpZUnYWSjmvdGltp76e4mobn82fch3MFWlBJYsepYO1Vw9Xx3DXI3CvBAfALpUJevfLAB6k/s1600-h/D-Window-(3).jpg"><span style="font-family:trebuchet ms;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5370626778326047394" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgwBHu8AAOgZu3bW0zmJXNCxFVIPFka0A1hqxVXtCSf6KZJOzKUFYM4a-k1TIeYRe0LCDHeEpZUnYWSjmvdGltp76e4mobn82fch3MFWlBJYsepYO1Vw9Xx3DXI3CvBAfALpUJevfLAB6k/s200/D-Window-(3).jpg" /></span></a><br /><span style="font-family:trebuchet ms;font-size:85%;">The basic window frame was cut form 0.020" NS4 aluminium using a band saw. The inner curves being cut with a fly cutter and a similar process was used to cut out the outer frame. finishing was achieved using aluminium nibblers and lots of filing starting with a course file and gradually finer files until the final finish using fine grit paper.</span><br /><span style="font-family:trebuchet ms;font-size:85%;"></span><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgJ7HdnnVe3DF5HcVAGmI-1yTNHt_3_pzA54O06Fenouh5qeTktL-rx-OQhCAlCS_cqdJXDys7Xz8TIXJoRWNJVYeS3-KV2L3u76YrENUTQOrcO1uDR0isdiFkfeYN5NkKIjFxmADG1ZIA/s1600-h/D-Window-(5).jpg"><span style="font-family:trebuchet ms;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5370626789238054450" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgJ7HdnnVe3DF5HcVAGmI-1yTNHt_3_pzA54O06Fenouh5qeTktL-rx-OQhCAlCS_cqdJXDys7Xz8TIXJoRWNJVYeS3-KV2L3u76YrENUTQOrcO1uDR0isdiFkfeYN5NkKIjFxmADG1ZIA/s200/D-Window-(5).jpg" /></span></a><span style="font-family:trebuchet ms;font-size:85%;"> </span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEglpBTTsSTSrnPIf4c7O0qw2MKmjQJlJUL9gnGD8nHieFDRc_E3ckmFEqWYVz8HylFliXhY9v3sSep01h7xmLb4iY8VLIjScvLoWmLGwAw-zM6RWa8U3e_QcAnBHEavnYjd1xkw_Gzb_Ig/s1600-h/D-Window-(6).jpg"><span style="font-family:trebuchet ms;font-size:85%;"><img style="WIDTH: 134px; HEIGHT: 200px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5370627200573745154" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEglpBTTsSTSrnPIf4c7O0qw2MKmjQJlJUL9gnGD8nHieFDRc_E3ckmFEqWYVz8HylFliXhY9v3sSep01h7xmLb4iY8VLIjScvLoWmLGwAw-zM6RWa8U3e_QcAnBHEavnYjd1xkw_Gzb_Ig/s200/D-Window-(6).jpg" /></span></a><span style="font-family:trebuchet ms;font-size:85%;"> </span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJlzA_XmkuWKXmdzUCdz_U9MnuW-mSwY68yJbSN-6_duXO8ODQxD53BpTTRSKrHQXit5_8okxEknilcA-Zt04dOC46yXbKQp5O7fQwtIJzreM2EnuwWV1-xu81R_2LVVkkKV1fK40jc68/s1600-h/D-Window-(7).jpg"><span style="font-family:trebuchet ms;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5370627204862537042" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJlzA_XmkuWKXmdzUCdz_U9MnuW-mSwY68yJbSN-6_duXO8ODQxD53BpTTRSKrHQXit5_8okxEknilcA-Zt04dOC46yXbKQp5O7fQwtIJzreM2EnuwWV1-xu81R_2LVVkkKV1fK40jc68/s200/D-Window-(7).jpg" /></span></a><br /><span style="font-family:trebuchet ms;font-size:85%;">The next step is to recess the main frame to take the 2mm Lexan glazing. This was done using Rob's metal rollers. Rob adapted the rollers so that they could take attachments for putting joggles into sheet metal. Manually adding the joggle to the inside of the main window frame resulted in a very pleasing finish although it introduces a warp across the sheet. The warp will be taken out when the edges of the window are bent to stiffen the frame.</span><br /><span style="font-family:trebuchet ms;font-size:85%;"></span><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqJZq55SXwSyZsePKoXuL376h4qFylSBagE64s32QS9Dwki7B4e5CAoVeRxWdLnNUMO7IEGbco164NpoGCf9-89y4nrSj7qr1PIvuNU_OkNmxX3uY_kG3y8RtI7XF54fqr2s_TMaWUf3s/s1600-h/D-Window-(8).jpg"><span style="font-family:trebuchet ms;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5370627205555165586" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqJZq55SXwSyZsePKoXuL376h4qFylSBagE64s32QS9Dwki7B4e5CAoVeRxWdLnNUMO7IEGbco164NpoGCf9-89y4nrSj7qr1PIvuNU_OkNmxX3uY_kG3y8RtI7XF54fqr2s_TMaWUf3s/s200/D-Window-(8).jpg" /></span></a><span style="font-family:trebuchet ms;font-size:85%;"> </span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuXav9SXQCepyxID3oj8Q2vdSTd4a9lmDpZqau88uGleUee5yCkTMz-6LrLHsV5A56jMyngIW1iMhNGaOlEh48NXK4Fh8TA5bojpMHETjDvE2_Tzwdvof9xkAQTcJCFzScsHc27zq6kUY/s1600-h/D-Window-(12).jpg"><span style="font-family:trebuchet ms;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5370627892579109554" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuXav9SXQCepyxID3oj8Q2vdSTd4a9lmDpZqau88uGleUee5yCkTMz-6LrLHsV5A56jMyngIW1iMhNGaOlEh48NXK4Fh8TA5bojpMHETjDvE2_Tzwdvof9xkAQTcJCFzScsHc27zq6kUY/s200/D-Window-(12).jpg" /></span></a><br /><span style="font-family:trebuchet ms;font-size:85%;">At this point the Lexan was cut to size and fitted to the frame. Remember to drill the holes in the Lexan slightly oversize to allow for expansion and contraction with the weather etc. Self tapping screws are used to hold the outer frame and Lexan to the inner frame.</span><br /><span style="font-family:trebuchet ms;font-size:85%;"></span><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgg9_FkfpGXfG2kEddATjyj9Jsbx853XPWz18xNky8oA5HvNTf4dC-f4EKwsGneoNwOPOgl2rpSTmDNBkIVWloNfEh_YtybdDO5SKxiqtYYWk0yt9FKEFSX7QWa9vapjeT2ZXey6qhyy0U/s1600-h/D-Window-(9).jpg"><span style="font-family:trebuchet ms;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5370627214763722338" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgg9_FkfpGXfG2kEddATjyj9Jsbx853XPWz18xNky8oA5HvNTf4dC-f4EKwsGneoNwOPOgl2rpSTmDNBkIVWloNfEh_YtybdDO5SKxiqtYYWk0yt9FKEFSX7QWa9vapjeT2ZXey6qhyy0U/s200/D-Window-(9).jpg" /></span></a><span style="font-family:trebuchet ms;font-size:85%;"> </span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgxwIpgNI2O591Reu4bceSzkwj6PiFZjnznjf2r_uXbrOYijAo8UyBAk6psT0JeHyV6Mi5MiMKYZ26-b8T8dWZE9lTaHKCrpud2XpCwtfQ72EmvO2oW1KIbdRe90x5ramsdDBESro8OSyU/s1600-h/D-Window-(11).jpg"><span style="font-family:trebuchet ms;font-size:85%;"><img style="WIDTH: 200px; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5370627884005795554" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgxwIpgNI2O591Reu4bceSzkwj6PiFZjnznjf2r_uXbrOYijAo8UyBAk6psT0JeHyV6Mi5MiMKYZ26-b8T8dWZE9lTaHKCrpud2XpCwtfQ72EmvO2oW1KIbdRe90x5ramsdDBESro8OSyU/s200/D-Window-(11).jpg" /></span></a><br /><span style="font-family:trebuchet ms;font-size:85%;">Finally, the frame is bent at the edges to add stiffness to the whole assembley and provide a surface to mate with the door frame. There is still one or two minor tasks to do with fixing the window to the door frame mainly to do with cutting slots around the door frame mounts so once this is done I'll post pictures of the windows in situ.</span><br /><span style="font-family:trebuchet ms;font-size:85%;"></span><br /><span style="font-family:trebuchet ms;font-size:85%;">I've also sent the fuel tanks off to have new fittings welded in and have the tanks pressure tested and have sent all the tail feathers off to have some remedial welding done. At the time of writing, these are back so the next blog will probably show the results of the welding and the work that is progressing on the renovated tail feathers.</span><br /><span style="font-family:trebuchet ms;font-size:85%;"></span>Andy Dukehttp://www.blogger.com/profile/09382605630219566798noreply@blogger.com0tag:blogger.com,1999:blog-3930866049742766350.post-91375748048652977772009-05-05T10:28:00.006+01:002009-05-05T11:47:43.625+01:00A new set of aileron hinges<span style="font-family:verdana;font-size:85%;">One of the common maintenance issues with Taylorcrafts is th onset of wear in the aileron hinges caused by the hinge rotating against the clevis pin. This is often noticable on the outer hinges and can be checked by pushing the aileron up at the tip; you will feel the movement on the hinge, it's fairly obvious. A small amount of wear is acceptable but as mine are worn to a point where they are only just acceptable I've been on the lookout for a new set of hinges. </span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhXJQcjVf8eYxm0Xjsg6JWSAjjbrh3ZUmyEmFo97XJn6Yz8zBzhvAZ890WfQnmXAy0JBlHXXcHEbGvg7rtnF8Q_Fo1WpdwLv2y4JJXLOLlUTvIvnVgQrd9q43pNMHGHn0S0PNmAMaVMzw/s1600-h/AileronHinge-(2).jpg"><span style="font-family:verdana;font-size:85%;"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 200px; FLOAT: left; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5332271663022789458" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhXJQcjVf8eYxm0Xjsg6JWSAjjbrh3ZUmyEmFo97XJn6Yz8zBzhvAZ890WfQnmXAy0JBlHXXcHEbGvg7rtnF8Q_Fo1WpdwLv2y4JJXLOLlUTvIvnVgQrd9q43pNMHGHn0S0PNmAMaVMzw/s200/AileronHinge-(2).jpg" /></span></a><span style="font-family:verdana;font-size:85%;">Initially I approached the Factory but due to complications regarding the export of stock oversees, and the fact I discovered that I had Rob's jig for the job, I decided that it would be just as easy to make a new set. The jig, in two parts forms the basic shape of the hinge and allows the mounting and pivit holes to be drilled and reemed.</span><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhXJQcjVf8eYxm0Xjsg6JWSAjjbrh3ZUmyEmFo97XJn6Yz8zBzhvAZ890WfQnmXAy0JBlHXXcHEbGvg7rtnF8Q_Fo1WpdwLv2y4JJXLOLlUTvIvnVgQrd9q43pNMHGHn0S0PNmAMaVMzw/s1600-h/AileronHinge-(2).jpg"><span style="font-family:verdana;font-size:85%;"></span></a><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;">The basic set of six hinges took a weekend to make using the jig and some 0.050" 4130 steel sheet.</span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuywZh7-s23QmCY9loYDg9vAGmEQL7WPqVN8drvisUb5d1yjVLrLlDNXCO2ew1CVmW0IVriRsOzK2b_5CsIy4OStB3SWUVQnIMdtP_93TIWrIjV7elsS8wM-yT7sVXo3yXHTCGiCTQFis/s1600-h/AileronHinge-(1).jpg"><span style="font-family:verdana;font-size:85%;"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 200px; FLOAT: left; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5332271661567879138" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuywZh7-s23QmCY9loYDg9vAGmEQL7WPqVN8drvisUb5d1yjVLrLlDNXCO2ew1CVmW0IVriRsOzK2b_5CsIy4OStB3SWUVQnIMdtP_93TIWrIjV7elsS8wM-yT7sVXo3yXHTCGiCTQFis/s200/AileronHinge-(1).jpg" /></span></a><span style="font-family:verdana;font-size:85%;">1) Six oversize blanks were cut from the sheet steel. The size is sufficient that each piece fits snuggly in the jig ready for pressing.</span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEisyVrkxgdpuD5CxrH-qCMYl7P3OfSYLc9A7WxZJzpxqdl-gHtUtgeFmSehlo6lTbs0zgqlYs_r8dp37rbdh_xkioqTh2zFq8ONvzVU3NxdA5oaVKYCVrC6aioWaO9AEpTHfYf4PCuZWe0/s1600-h/AileronHinge-(3).jpg"><span style="font-family:verdana;font-size:85%;"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 200px; FLOAT: left; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5332271664358247394" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEisyVrkxgdpuD5CxrH-qCMYl7P3OfSYLc9A7WxZJzpxqdl-gHtUtgeFmSehlo6lTbs0zgqlYs_r8dp37rbdh_xkioqTh2zFq8ONvzVU3NxdA5oaVKYCVrC6aioWaO9AEpTHfYf4PCuZWe0/s200/AileronHinge-(3).jpg" /></span></a><span style="font-family:verdana;font-size:85%;">2) The basic shape is pressed using a vice.</span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:Verdana;font-size:85%;"></span><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgDtfm44j37VkGwZuRwP9tUb9olUeATzuutv_H3qv3oej7J5D5k2P83VIOMGdZJzvxak-IdVjyQWbgnzUIGHSe6RY_Ty-hbhA9m4_zJQSidOdHKE5i0lRaJdi8TEr1wR6ZW_1qCCENaUc/s1600-h/AileronHinge-(4).jpg"><span style="font-family:verdana;font-size:85%;"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 200px; FLOAT: left; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5332271666225473362" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgDtfm44j37VkGwZuRwP9tUb9olUeATzuutv_H3qv3oej7J5D5k2P83VIOMGdZJzvxak-IdVjyQWbgnzUIGHSe6RY_Ty-hbhA9m4_zJQSidOdHKE5i0lRaJdi8TEr1wR6ZW_1qCCENaUc/s200/AileronHinge-(4).jpg" /></span></a><br /><span style="font-family:verdana;font-size:85%;"> 3) While still in the jig, the mounting and pivit holes are drilled and reamed.<br /></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;"><br /><br /></span><span style="font-family:verdana;"><span style="font-size:85%;"></span></span><span style="font-family:verdana;font-size:85%;"></span><br /><br /> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXARsAPtM9Fe3rjCfpdTUEhCKOAsFiNh1S3IyeQ5wElE1Ma1OtRjNyHo_xHOMxAlmPy6WcD8QTZvDHSepmLLo31EvT3QodC90ZG9ln5XwJiXkGGiFFp7T0ABUo3aFXMeHqShawH7OjAPQ/s1600-h/AileronHinge-(5).jpg"><span style="font-family:verdana;font-size:85%;"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 200px; FLOAT: left; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5332271666450340882" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXARsAPtM9Fe3rjCfpdTUEhCKOAsFiNh1S3IyeQ5wElE1Ma1OtRjNyHo_xHOMxAlmPy6WcD8QTZvDHSepmLLo31EvT3QodC90ZG9ln5XwJiXkGGiFFp7T0ABUo3aFXMeHqShawH7OjAPQ/s200/AileronHinge-(5).jpg" /></span></a><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:Verdana;font-size:85%;"></span><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhJRtOIDRUJRwny_43fTxVlmgl0M6qmY9iW6SfU-vjJYGT6XCl-bFIM_CcP1tKHJK5a2vb8UTCVYlFdDmNJpzOWAPHDQOBRQvLg9n5M67ON6Cf1QjcY9bybkMN1nGx7-z_9K8vQdNSAY8/s1600-h/AileronHinge-(6).jpg"><span style="font-family:verdana;font-size:85%;"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 200px; FLOAT: left; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5332272790717844178" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhJRtOIDRUJRwny_43fTxVlmgl0M6qmY9iW6SfU-vjJYGT6XCl-bFIM_CcP1tKHJK5a2vb8UTCVYlFdDmNJpzOWAPHDQOBRQvLg9n5M67ON6Cf1QjcY9bybkMN1nGx7-z_9K8vQdNSAY8/s200/AileronHinge-(6).jpg" /></span></a><span style="font-family:verdana;font-size:85%;">4) The blanks are roughly shaped (original hinge shown for comparrison).</span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:Verdana;font-size:85%;"></span><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhvdXHz1AOJFD-mRtVjuZPzuYfI9bA5ZfyQb0L16I1imdkI3JGLyjHYxYW24Plixq6203UXPb7HwGBgpwwQigR3QaE5VOORMRgx1vTB-9EQ2Eile9FC4wiUCChslMgOfVi9r6gbiW3iug/s1600-h/AileronHinge-(7).jpg"><span style="font-family:verdana;font-size:85%;"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 200px; FLOAT: left; HEIGHT: 132px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5332272797076434674" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhvdXHz1AOJFD-mRtVjuZPzuYfI9bA5ZfyQb0L16I1imdkI3JGLyjHYxYW24Plixq6203UXPb7HwGBgpwwQigR3QaE5VOORMRgx1vTB-9EQ2Eile9FC4wiUCChslMgOfVi9r6gbiW3iug/s200/AileronHinge-(7).jpg" /></span></a><span style="font-family:verdana;font-size:85%;">5) Final finishing with file and wet/dry paper and comparrison with an original hinge.</span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><br /><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghCkHySgZdoT5GtODVwxw4apeKu8EdqYif0djkbw_h2OCjQkAGxY8sJwCPR4OYd894lh9u3v-UfCHJ05SmwbWvgiyxqSi5dQME4U2PjAZeIZenH60SHCsd59roYIO54k3jY4SCN3iApws/s1600-h/AileronHinge-(8).jpg"><span style="font-family:verdana;font-size:85%;"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 200px; FLOAT: left; HEIGHT: 137px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5332272795289262242" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghCkHySgZdoT5GtODVwxw4apeKu8EdqYif0djkbw_h2OCjQkAGxY8sJwCPR4OYd894lh9u3v-UfCHJ05SmwbWvgiyxqSi5dQME4U2PjAZeIZenH60SHCsd59roYIO54k3jY4SCN3iApws/s200/AileronHinge-(8).jpg" /></span></a><span style="font-family:verdana;font-size:85%;">6) The final modification is to spot weld a tab onto the hinge to provide a flat. Each clevis pin will have a flat filed to fit thus preventing the pin from turning against the hinge.<br /><br /></span><span style="font-family:verdana;font-size:85%;"></span><span style="font-family:verdana;font-size:85%;"><br /><br /><br /></span><div> </div><div> </div><div><span style="font-size:85%;">Lastly, my thanks must go to Rob Lees and David Nowill, who between them, designed and manufactored the jig, and then let me use it.</span></div>Andy Dukehttp://www.blogger.com/profile/09382605630219566798noreply@blogger.com0tag:blogger.com,1999:blog-3930866049742766350.post-33353144673266344732009-05-05T10:21:00.006+01:002009-05-05T14:07:47.276+01:00Finishing the Ailerons<span style="font-family:verdana;font-size:85%;">I have finally gotten two refurbished ailerons, but before I put them to one side, I wanted to check that everything fits in relation to the wings. I'm basically using the wings as a jig to check the alignment of the ailerons with the new hinges.</span><br /><br /><span style="font-family:verdana;font-size:85%;"></span><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJ3j7LhzCYuZ-FSly-QPPo8LSKoELOpgvgGfCxGff6wvp2nBzGTk9ete1Z0NkWVPN1PooTF9qBy2chjyQW40gUK5fvtVHZqavxVoF42mpa109JI8JAcrZq2-DMgru4mvIzSif3ZgZg2Qg/s1600-h/Aileron-(37).jpg"><span style="font-family:verdana;font-size:85%;"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 134px; FLOAT: left; HEIGHT: 200px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5332267996178934018" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJ3j7LhzCYuZ-FSly-QPPo8LSKoELOpgvgGfCxGff6wvp2nBzGTk9ete1Z0NkWVPN1PooTF9qBy2chjyQW40gUK5fvtVHZqavxVoF42mpa109JI8JAcrZq2-DMgru4mvIzSif3ZgZg2Qg/s200/Aileron-(37).jpg" /></span></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKRNc-loNIEQi1AlGbrifAQdO-3urH3b1nxgdXNLg4asbYLsckBlt_NaRk9B89XXajbFHw2ROKIS2pVHB1OCbPLQXYHn9ae0ftTvUawrJrwThn5_wPbBv0Ee-mb1UkXoSEj2-3GkgJdUA/s1600-h/Aileron-(36).jpg"><span style="font-family:verdana;font-size:85%;"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 134px; FLOAT: left; HEIGHT: 200px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5332267996818220914" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKRNc-loNIEQi1AlGbrifAQdO-3urH3b1nxgdXNLg4asbYLsckBlt_NaRk9B89XXajbFHw2ROKIS2pVHB1OCbPLQXYHn9ae0ftTvUawrJrwThn5_wPbBv0Ee-mb1UkXoSEj2-3GkgJdUA/s200/Aileron-(36).jpg" /></span></a><span style="font-family:verdana;font-size:85%;">The port aileron fits without a hitch but the alignment on the butt rib of the starboard aileron is out for some reason and of course I've no photograph to check the alignment prior to the rebuild.<br /><br /><br /><br /></span><br /><br /><span style="font-family:verdana;font-size:85%;"></span><br /><br /><span style="font-family:verdana;font-size:85%;"></span><br /><br /><span style="font-family:verdana;font-size:85%;"></span><br /><br /><span style="font-family:verdana;"><br /><span style="font-size:85%;"></span></span><br /><br /><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizR-QTSpBLoL_QkvPK6CQZkIZSh-9lMXeuYCrZjvM3sKRi74PMMWNsUy517AFMRptdv8V7tNrisoOv6xGbFb24-mIXYDd4W468cV1R-ePPk2gCjFeTc35-wfqiNB_fIjdRsVz-b7VfTb4/s1600-h/Aileron-(35).jpg"><span style="font-family:verdana;font-size:85%;"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 200px; FLOAT: left; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5332267995632214114" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizR-QTSpBLoL_QkvPK6CQZkIZSh-9lMXeuYCrZjvM3sKRi74PMMWNsUy517AFMRptdv8V7tNrisoOv6xGbFb24-mIXYDd4W468cV1R-ePPk2gCjFeTc35-wfqiNB_fIjdRsVz-b7VfTb4/s200/Aileron-(35).jpg" /></span></a><span style="font-family:verdana;font-size:85%;"> The extent to which the but rib is out of alignment can be gauged by looking at this photo, about 1 cm at the trailing edge.<br /><br /></span></div><br /><div><span style="font-family:verdana;font-size:85%;"></span></div><span style="font-family:verdana;"><br /><div><br /></div><br /><div><br /></div><span style="font-size:85%;"></span></span><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjY5e3hUwJCEj_-y_vzN2qBNhJYJxJj1KGgrDgAuUVKO4PQfykXThAx5fmhmYxyP8vb90LrghtqQNQElMt1GjbEV0pWv3wca8Ha1eZntGXw-lZBMqgpdZaPzo5gyCWiCC3LB-Y1FHIUbKY/s1600-h/Aileron-(34).jpg"><span style="font-family:verdana;font-size:85%;"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 200px; FLOAT: left; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5332267991995816530" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjY5e3hUwJCEj_-y_vzN2qBNhJYJxJj1KGgrDgAuUVKO4PQfykXThAx5fmhmYxyP8vb90LrghtqQNQElMt1GjbEV0pWv3wca8Ha1eZntGXw-lZBMqgpdZaPzo5gyCWiCC3LB-Y1FHIUbKY/s200/Aileron-(34).jpg" /></span></a><span style="font-family:verdana;font-size:85%;"> To rectify this, I've used a piece of trailing edge, cut down so that it forms a box section that will fit inside the existing trailing edge when it is cut.</span></div><br /><div><span style="font-family:verdana;"><br /><br /><br /><br /><span style="font-size:85%;"></span></span></div><div><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgE8p4ZyStB0_-1XkS6S4pydLisVAZerVHyI3FIn4UZ18jTEMi5n7k36G0TvgMK6s2wXnZQN2gMICtR33Ed5p9g9bIqBl0llHw-0qJBZrYSbxWbyCNgs1y2z_6NQ4ZHAellyzAf5CfBjIM/s1600-h/Aileron-(33).jpg"><span style="font-family:verdana;font-size:85%;"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 200px; FLOAT: left; HEIGHT: 134px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5332267991833350786" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgE8p4ZyStB0_-1XkS6S4pydLisVAZerVHyI3FIn4UZ18jTEMi5n7k36G0TvgMK6s2wXnZQN2gMICtR33Ed5p9g9bIqBl0llHw-0qJBZrYSbxWbyCNgs1y2z_6NQ4ZHAellyzAf5CfBjIM/s200/Aileron-(33).jpg" /></span></a><span style="font-family:verdana;font-size:85%;">After riviting, I will fill the gap with micro balloon filler so that the repair will be less obvious. The rivit heads will be visible because they couldn't be countersunk but tey are no worse than screw heads used all along the trailing edge.<br /><br /><br /><br /><br /></span></div><br /><div><span style="font-family:verdana;font-size:85%;">I've checked the fit after the repair which gives a much better fit now with the wing. The ailerons will now be put aside, uncovered, until I come to rig the aircraft way in the future. </span></div><br /><div><span style="font-family:Verdana;font-size:85%;"></span></div><br /><div><span style="font-family:Verdana;font-size:85%;">Now back to the fuselage and a lot of welding work....</span></div>Andy Dukehttp://www.blogger.com/profile/09382605630219566798noreply@blogger.com0tag:blogger.com,1999:blog-3930866049742766350.post-68487396524904587932009-03-09T10:15:00.011+00:002009-03-09T11:53:14.159+00:00Ailerons and Skylights<span style="font-family:verdana;"><span style="font-size:85%;"><u>Aileron</u><br /><br /></span></span><span style="font-family:verdana;"><span style="font-size:85%;"></span></span><span style="font-family:verdana;font-size:85%;">Just a quick update on the progress of the 2nd aileron. Firstly all the ribs, leading edge, trailing edge and hardware have been cleaned, etch primed and epoxied and are ready for reattaching to the spar. The spar has had some repairework carried out to fix the crushing similar to the first spar. There was also a minor crack running lengthways along the spar from the but, about 6" long and about half the depth of the spar. This will be patched as the majority of the crack lies under a plywood reinforcement plate. The spar had a second coat of varnish at the weekend so I shall be able to start reassembling the aileron next weekend (although I may have to do some gardening as well!).</span><br /><br /><span style="font-family:verdana;"><span style="font-size:85%;"><u>Skylight</u><br /><br /></span></span><span style="font-family:verdana;"><span style="font-size:85%;"></span></span><span style="font-family:verdana;font-size:85%;">In the mean time, I progress with the skylight woodwork.</span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikwLWGNsqvjx1biSqXMzEr4LT2iGmVbJzJmAhd3BsE8v1fx0I8cDLfu4sqizZ03TQw26SZkwlE5Z30YBknFzeDNezqq-UgFcVLWo-VCo6Y0DzEQ3JY2QdukK2-0lsIAUJP2yc0PQu3KtQ/s1600-h/Skylight-(IV).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5311140071398617970" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 200px; CURSOR: hand; HEIGHT: 134px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikwLWGNsqvjx1biSqXMzEr4LT2iGmVbJzJmAhd3BsE8v1fx0I8cDLfu4sqizZ03TQw26SZkwlE5Z30YBknFzeDNezqq-UgFcVLWo-VCo6Y0DzEQ3JY2QdukK2-0lsIAUJP2yc0PQu3KtQ/s200/Skylight-(IV).jpg" border="0" /></span></a><span style="font-family:verdana;font-size:85%;"> </span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;">Lets refresh our memories of the old skylight. It extended from the windshield back for nearly two bays, held in place by wooden formers and steel angle (see below). </span><br /><p></p><p></p><br /><br /><span style="font-family:verdana;font-size:85%;"></span><br /><br /><span style="font-family:verdana;font-size:85%;"><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFENMrIaSa3KLbPtBmzFGWXutpPvzrq-L8MgjpzTxAq8EEb7xCHuYE-5m2fdd8JZyu1IT1Ss4RxseG0AvPEGZL0C9JlmOjHsY-c3p6QzhqJZXp4UJF3zKpNl6TiM7Il80_08DIE5CKG-0/s1600-h/Skylight-(7).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5311138110454039762" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 134px; CURSOR: hand; HEIGHT: 200px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFENMrIaSa3KLbPtBmzFGWXutpPvzrq-L8MgjpzTxAq8EEb7xCHuYE-5m2fdd8JZyu1IT1Ss4RxseG0AvPEGZL0C9JlmOjHsY-c3p6QzhqJZXp4UJF3zKpNl6TiM7Il80_08DIE5CKG-0/s200/Skylight-(7).jpg" border="0" /></span></a></div>The second bay does not increase the viewable area and just adds to the weight of the aircraft for no advantage; so on the rebuild I </span><span style="font-family:verdana;font-size:85%;">will stick to a single piece skylight covering the first bay only.</span><br /><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFENMrIaSa3KLbPtBmzFGWXutpPvzrq-L8MgjpzTxAq8EEb7xCHuYE-5m2fdd8JZyu1IT1Ss4RxseG0AvPEGZL0C9JlmOjHsY-c3p6QzhqJZXp4UJF3zKpNl6TiM7Il80_08DIE5CKG-0/s1600-h/Skylight-(7).jpg"><span style="font-family:verdana;font-size:85%;"></span></a><br /><br /><br /><span style="font-family:verdana;font-size:85%;"></span><br /><br /><br /><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTEUlHpTKthCW6mfvs_J5MPK4TA9UZ776au14H2Bf0rrnJ4QfGPtCTB5to1JWu2RerpNz83cDpZrbYtWwznYcNUHaeD1DHxhC8Fd7F7uv4byeRIkK7yoLHO3rz7LLsvrC1FLDKtdIU0AY/s1600-h/Skylight-(8).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5311139026725471618" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 200px; CURSOR: hand; HEIGHT: 134px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTEUlHpTKthCW6mfvs_J5MPK4TA9UZ776au14H2Bf0rrnJ4QfGPtCTB5to1JWu2RerpNz83cDpZrbYtWwznYcNUHaeD1DHxhC8Fd7F7uv4byeRIkK7yoLHO3rz7LLsvrC1FLDKtdIU0AY/s200/Skylight-(8).jpg" border="0" /></span></a><br /><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;">The frame will be made from the same Ash plank used to make the door frames, using the existing frames as a template. These are rough cut with a band saw then shaped with a spoke shave and finished by sanding. Various notches where cut with a fine chisel.</span><br /><br /><br /><span style="font-family:verdana;font-size:85%;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgMdnMEyUpw0wyRC56TNZg7sFbiOEhNEpJYIB92-_QNg3YiBEeKUHovfEGaQnUxK7rtRKCoi5Z6-tKPbnbGJ0n2LMU-6GxV8Ytz_t3Z-Z4qXlMYiUhsWgq6uUwXudXFqptisIJ2oJ5Bh3I/s1600-h/Skylight-(6).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5311135803663921058" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 200px; CURSOR: hand; HEIGHT: 134px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgMdnMEyUpw0wyRC56TNZg7sFbiOEhNEpJYIB92-_QNg3YiBEeKUHovfEGaQnUxK7rtRKCoi5Z6-tKPbnbGJ0n2LMU-6GxV8Ytz_t3Z-Z4qXlMYiUhsWgq6uUwXudXFqptisIJ2oJ5Bh3I/s200/Skylight-(6).jpg" border="0" /></span></a>Some time later after many trial fits, the basic frame sits on the fuselage. Note that instead of using a piece of steel angle on the sides, I'm using 1" thick wood (still much lighter).</span><br /><br /><br /><br /><br /><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj81VO97VVP6JgXM1uvTiFeVH5Rm08K4bPk-M1meEsF6ACF5Mowb-Ws0GC0GTrGjHYus8-SrT8PL1uI4SmU2IKP8fVlikDoPRbsH24vOECJwh-BUFy0dSqQLc41HncEm0L9CrftWXswFlc/s1600-h/ProngedTee.jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5311148347197941026" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 200px; CURSOR: hand; HEIGHT: 200px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj81VO97VVP6JgXM1uvTiFeVH5Rm08K4bPk-M1meEsF6ACF5Mowb-Ws0GC0GTrGjHYus8-SrT8PL1uI4SmU2IKP8fVlikDoPRbsH24vOECJwh-BUFy0dSqQLc41HncEm0L9CrftWXswFlc/s200/ProngedTee.jpg" border="0" /></span></a>My plan is to fix the skylight (3mm clear acrylic sheet) to the frame by embedding a threaded insert (below) into the underside of the frame that I can screw into. In addition I will have four internally threaded steel tubes welded to the cross frame of the fuselage which will suport the skylight and give it some rigidity<br /><br />I hope to pick up the acrylic sheet next week which will be cut to shape, drilled and used to determine the location of the threaded inserts.</span><br /><span style="font-family:Verdana;font-size:85%;"></span><br /><span style="font-family:Verdana;font-size:85%;"></span><br /><span style="font-family:Verdana;font-size:85%;"></span><br /><span style="font-family:Verdana;font-size:85%;"></span><br /><span style="font-family:Verdana;font-size:85%;"></span><br /><span style="font-family:Verdana;font-size:85%;">Next week I'll try and update you with the aileron reassembley and possibly a bit more on skylight progress. Untill then happy flying.</span>Andy Dukehttp://www.blogger.com/profile/09382605630219566798noreply@blogger.com1tag:blogger.com,1999:blog-3930866049742766350.post-80542409849747581872009-01-11T15:26:00.005+00:002009-01-11T16:14:13.412+00:00First Aileron Complete and a New Hat Shelf<span style="font-family:verdana;font-size:85%;"><br /></span><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh53oYPW9NeQ2bk551wp_hJAu638ygxL-K0o9Iwu2dfDD2WVnrR7OWRnuIDzGm-oTBkjIkcsmVAxJnkLDXg1NJihf-Mgwg52dRRdIty6xXOExeN7xu6eShwjP6GkkLs2EgddS5FFmZSfPk/s1600-h/Aileron-(30).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5290062768730341138" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 200px; CURSOR: hand; HEIGHT: 123px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh53oYPW9NeQ2bk551wp_hJAu638ygxL-K0o9Iwu2dfDD2WVnrR7OWRnuIDzGm-oTBkjIkcsmVAxJnkLDXg1NJihf-Mgwg52dRRdIty6xXOExeN7xu6eShwjP6GkkLs2EgddS5FFmZSfPk/s200/Aileron-(30).jpg" border="0" /></span></a><span style="font-family:verdana;font-size:85%;"> A few photo's of the completed starboard aileron showing the strenghtened but rib. </span></div><br /><div><span style="font-family:verdana;font-size:85%;"></span></div><br /><div><span style="font-family:verdana;font-size:85%;"></span></div><br /><div><span style="font-family:verdana;font-size:85%;"></span></div><br /><div><span style="font-family:verdana;font-size:85%;"></span></div><br /><div><span style="font-family:verdana;font-size:85%;"></span></div><div><span style="font-family:verdana;font-size:85%;"></span></div><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7bQfpjv2dwI1-YdRT91vZdf8aadFn3zugZbUTNJqdOiCC3ErE_bbIFvAzjNRNhYZf-1AuRcRMDZyKaN0oBrMW7JWck7Ikb8kWnCeU_dAgF-w8LFAOFy3cFSlkNoGKyh7ovyqix2aCz2w/s1600-h/Aileron-(29).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5290062765349742882" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 200px; CURSOR: hand; HEIGHT: 134px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7bQfpjv2dwI1-YdRT91vZdf8aadFn3zugZbUTNJqdOiCC3ErE_bbIFvAzjNRNhYZf-1AuRcRMDZyKaN0oBrMW7JWck7Ikb8kWnCeU_dAgF-w8LFAOFy3cFSlkNoGKyh7ovyqix2aCz2w/s200/Aileron-(29).jpg" border="0" /></span></a></div><div><span style="font-family:verdana;font-size:85%;">The tip end rib also had to be replaced as the wood was cracked and had lost much (if not all) of it's residual strength.</span></div><br /><div><span style="font-family:verdana;"><br /><span style="font-size:85%;"></span></span></div><br /><div><br /><div> </div><div> </div><div><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPKT7KmpDO_Iut8BRp69nNUyW5kEFMiUHDc1DFuMiBseVYTaOuSo7JAgqn5x8JA2-2x2L5Z4OCh_kjcIr5ZHezufbi_43rXRfjopZS_nUGnSZ_938nBhpvl1xMGrFB-ds-DSuMo5gaN0A/s1600-h/Aileron-(32).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5290062774624216034" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 200px; CURSOR: hand; HEIGHT: 52px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPKT7KmpDO_Iut8BRp69nNUyW5kEFMiUHDc1DFuMiBseVYTaOuSo7JAgqn5x8JA2-2x2L5Z4OCh_kjcIr5ZHezufbi_43rXRfjopZS_nUGnSZ_938nBhpvl1xMGrFB-ds-DSuMo5gaN0A/s200/Aileron-(32).jpg" border="0" /></span></a><span style="font-family:verdana;font-size:85%;"> Two general pictures showing the end result.</span></div><div><span style="font-family:Verdana;font-size:85%;"></span> </div><div><span style="font-family:verdana;font-size:85%;"></span> </div><br /><div><span style="font-family:verdana;font-size:85%;"></span></div><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_gRlFQkiXZKPM_btxE22e3JtdvI5_LqDkBU-zcLvCz-_7FLLGf7Liund7iOeto6Jryk97lU_8Ix4CavtM0bkSTkPASdRCc1A2IyJgemCQRbJIKt_n7gY7vriKxnOpi1jWZP1YdDqUdNY/s1600-h/Aileron-(31).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5290062774293245602" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 200px; CURSOR: hand; HEIGHT: 50px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_gRlFQkiXZKPM_btxE22e3JtdvI5_LqDkBU-zcLvCz-_7FLLGf7Liund7iOeto6Jryk97lU_8Ix4CavtM0bkSTkPASdRCc1A2IyJgemCQRbJIKt_n7gY7vriKxnOpi1jWZP1YdDqUdNY/s200/Aileron-(31).jpg" border="0" /></span></a></div><div><span style="font-family:verdana;font-size:85%;"></span> </div><div><span style="font-family:verdana;font-size:85%;"></span> </div><div><span style="font-family:verdana;font-size:85%;"></span> </div><div><span style="font-family:verdana;font-size:85%;"><br /></span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLxtgixUQih7cO86PXuKzNvT7lq9j3idq8H0xvVK5EnHnPWeeDuQvPM8aevfU8RjvKD3qH6C5aMSZGvmgCz3-o2KCm1iUrq_gANUs77Ud9DbfmpeWwGTOUm3WmVt3yxK_9LC-PsKpstSE/s1600-h/HatShelf-(1).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5290066496711064946" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 200px; CURSOR: hand; HEIGHT: 130px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLxtgixUQih7cO86PXuKzNvT7lq9j3idq8H0xvVK5EnHnPWeeDuQvPM8aevfU8RjvKD3qH6C5aMSZGvmgCz3-o2KCm1iUrq_gANUs77Ud9DbfmpeWwGTOUm3WmVt3yxK_9LC-PsKpstSE/s200/HatShelf-(1).jpg" border="0" /></span></a><span style="font-family:verdana;font-size:85%;">Although I will be starting on the second aileron next week I have also started looking at the design of a map shelf to fit behind the baggage sling. The design (I admit) was taken from that used by Rob in the restoration of G-BREY. Steel tabs will be welded to the fuselage so that the aluminium shelf can be screwed in place with machine screws. The map shelf is large enough that it require stiffening to prevent it from sagging even though it is not intended to support any real weight. It is far enough to the rear of the aircraft that any weight in this area will impact on the c of g of the aircraft.</span></div><span style="font-family:verdana;font-size:85%;"></span></div><div><span style="font-family:verdana;font-size:85%;">Next week I'll post more details on the design of the map shelf and the stiffeners to be used. <div><br /></div></span><br /><div><span style="font-family:verdana;font-size:85%;"></span></div></div></div>Andy Dukehttp://www.blogger.com/profile/09382605630219566798noreply@blogger.com0tag:blogger.com,1999:blog-3930866049742766350.post-74555024687252785342009-01-01T18:34:00.007+00:002009-01-01T21:13:21.563+00:00Completing the first Aileron<span style="font-family:verdana;font-size:85%;">By early December the spars have had all the plywood doublers glued in place, drilled for the aileron brackets and varnished with Randolf spar varnish. The ribs are in place but not yet nailed and most other components are primed ready for reassembly.</span><span style="font-family:verdana;"> </span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1w3JKXMUGlFCfKfZgCdS9isDfIMYUJKNxtBjr39Obp-2_1unbmCxMVS4KkLTKhRS6xY5WUStWoXH6w7Y88KnmGRxnCd1Q54z6JpG1nbFvAFXAxkjrGdhzHpQMUMozIYkfkDgex2aKdC4/s1600-h/Aileron-(XXI).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5286396043061990050" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 200px; CURSOR: hand; HEIGHT: 134px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1w3JKXMUGlFCfKfZgCdS9isDfIMYUJKNxtBjr39Obp-2_1unbmCxMVS4KkLTKhRS6xY5WUStWoXH6w7Y88KnmGRxnCd1Q54z6JpG1nbFvAFXAxkjrGdhzHpQMUMozIYkfkDgex2aKdC4/s200/Aileron-(XXI).jpg" border="0" /></span></a> <span style="font-family:verdana;font-size:85%;">The first job is to nail the ribs in place. To achieve this I jigged the spar by mounting it onto the workbench with brackets attached with AN3 bolts through the holes drilled for the aileron brackets. I used the old nail holes to locate the position of each rib, and for completeness, screwed the trailing edge to the ribs. I was also able to offer up the leading edge skins to ensure the screw holes still lined up. Once confident that everything is in place, I nailed the ribs to the spar.<br /></span><br /><span style="font-family:verdana;font-size:85%;"><br /></span><span style="font-family:verdana;font-size:85%;"></span><span style="font-family:verdana;font-size:85%;">Following advice from Rob Lees (G-BREY), I decided to reinforce the butt rib as this has a tendency to bow in with the tension of the fabric when it is applied. A wedge was made from 0.020" 2024T3 aluminium which would fit inside the rib preventing it from warping. The wedge was riveted in place with blind rivets as I couldn't get a bucking bar in the space available if I was to use solid aluminium rivets. The three pictures below show the assembly of the wedge. </span><br /><span style="font-family:verdana;font-size:85%;"><br /></span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikP2i23aThuoxHgJcULE1qChQVi_Bn2p8DP1i0SomlJw3BQ5NJSMkOTisoWduZO5RIRyRLfFBaSZnIyYhQiJbr5QgFYvHH_tcus76q_GI_uxeaCDi3jbCV226QclDCxvilHGf42QxqMRA/s1600-h/Aileron-(XXII).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5286396046939994578" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 200px; CURSOR: hand; HEIGHT: 134px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikP2i23aThuoxHgJcULE1qChQVi_Bn2p8DP1i0SomlJw3BQ5NJSMkOTisoWduZO5RIRyRLfFBaSZnIyYhQiJbr5QgFYvHH_tcus76q_GI_uxeaCDi3jbCV226QclDCxvilHGf42QxqMRA/s200/Aileron-(XXII).jpg" border="0" /></span></a> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-n1a1q5VOuT79zUVuiJgMEKCUI86sJ5mjRZ25E6BW7hwMxQ9rCIRaEES7OV4m55WV6eaOzO87JYXpIpVCOOYSOZ-pcveMdagfmngmar1V-5iNnW5zgDhtJoxveGOCu3VXGRvnMgrnbp4/s1600-h/Aileron-(XXIII).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5286396049647247874" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 200px; CURSOR: hand; HEIGHT: 134px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-n1a1q5VOuT79zUVuiJgMEKCUI86sJ5mjRZ25E6BW7hwMxQ9rCIRaEES7OV4m55WV6eaOzO87JYXpIpVCOOYSOZ-pcveMdagfmngmar1V-5iNnW5zgDhtJoxveGOCu3VXGRvnMgrnbp4/s200/Aileron-(XXIII).jpg" border="0" /></span></a><span style="font-family:verdana;font-size:85%;"> </span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRk42szUpct4Oveo6dKrFBU6NiEVwBq0IctfOojPLYTbestv1yQZm30cfa7dp7Jw0dUzeer8UitdMbNM8rqrFWhXtJn2PnO_cjkjGdf839_yt6_2MEgumGs76k1MuHh9LOJ87FdLebY6M/s1600-h/Aileron-(XXIV).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5286396046792767282" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 200px; CURSOR: hand; HEIGHT: 134px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRk42szUpct4Oveo6dKrFBU6NiEVwBq0IctfOojPLYTbestv1yQZm30cfa7dp7Jw0dUzeer8UitdMbNM8rqrFWhXtJn2PnO_cjkjGdf839_yt6_2MEgumGs76k1MuHh9LOJ87FdLebY6M/s200/Aileron-(XXIV).jpg" border="0" /></span></a><span style="font-family:verdana;font-size:85%;"><br /></span><br /><span style="font-family:verdana;"><br /><span style="font-size:85%;"></span></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;"><br /><span style="font-size:85%;"></span></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><br /><span style="font-family:verdana;font-size:85%;">The aileron is made up mainly from aluminium parts except for the tip bow which is a 1/2" 4130 steel tube bent to shape and all screws which are stainless steel. Because there is the possibility of dissimilar metal corrosion where steel and aluminium come into contact (even though all parts are primed) I used Duralac, either painted on using a brush or as a dip with the screws which will act as an additional barrier preventing corrosion. The Duralac was wiped off after assembly to keep the structure clean. </span><span style="font-family:verdana;"><br /><span style="font-size:85%;"></span></span><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihGgSMH-6QdCkGDSICuBDy9SvI0b9pTKNvCcVY7JG6j6PoiHYslUs3HnnGUkErtIaPJTS1dYBpo2isC_1fSLcwhnVPLLwsQjKLju7AAU_a5TKHryeAQJzGGeNxPdBmOdAnXQPq1_e92NI/s1600-h/Aileron-(XXV).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5286396054134197922" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 200px; CURSOR: hand; HEIGHT: 134px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihGgSMH-6QdCkGDSICuBDy9SvI0b9pTKNvCcVY7JG6j6PoiHYslUs3HnnGUkErtIaPJTS1dYBpo2isC_1fSLcwhnVPLLwsQjKLju7AAU_a5TKHryeAQJzGGeNxPdBmOdAnXQPq1_e92NI/s200/Aileron-(XXV).jpg" border="0" /></span></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMswD7AQiPBboattNkiRaqzPIMxM9MzPcondoR6IEgXEqy6TapnBEbrxiKF3s2UwUFhsXttSGEGHIrC1YOV1LIQYKda7H9Pr9mNrwGxzWXNpy85viryCzHworissREd179ToZlbWiFKNc/s1600-h/Aileron-(XXVI).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5286396334731953506" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 200px; CURSOR: hand; HEIGHT: 134px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMswD7AQiPBboattNkiRaqzPIMxM9MzPcondoR6IEgXEqy6TapnBEbrxiKF3s2UwUFhsXttSGEGHIrC1YOV1LIQYKda7H9Pr9mNrwGxzWXNpy85viryCzHworissREd179ToZlbWiFKNc/s200/Aileron-(XXVI).jpg" border="0" /></span></a><br /><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;">The inside of the 4130 steel tip bow was treated with Lanolin (oil) to protect it from moisture which will also cause corrosion. Lanolin is the traditional British treatment whereas America tends to use Linseed oil instead. The downside to Linseed is that it is flamable which can be a problem if a weld repair is required at a later date.</span><br /><span style="font-family:Verdana;font-size:85%;"></span><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnncH1zaplCOvc2ixdvbD6t6lTX1o6eIC7hc5woAZmijzn6c91ZoKaHWRXKWjM_LhN1y8uWgxAKqrsy2d5R8ARoCMGMzv2Dg7gZ9_-dKTQhJprQ0_CbeXo4IF9MdI9ROm4xe3PlTTno60/s1600-h/Aileron-(XXVII).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5286396339669149938" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 200px; CURSOR: hand; HEIGHT: 134px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnncH1zaplCOvc2ixdvbD6t6lTX1o6eIC7hc5woAZmijzn6c91ZoKaHWRXKWjM_LhN1y8uWgxAKqrsy2d5R8ARoCMGMzv2Dg7gZ9_-dKTQhJprQ0_CbeXo4IF9MdI9ROm4xe3PlTTno60/s200/Aileron-(XXVII).jpg" border="0" /></span></a><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><br /><span style="font-family:verdana;font-size:85%;">Finally, the leading edges were screwed into place using the old screw holes. Oversize nails were used to secure theleading edge to the spar and the aileron brackets were bolted on. </span><br /><span style="font-family:Verdana;font-size:85%;"></span><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNiju76d9QHp76kAjx7iFoyPC4UKpaxHyo6MS8HvODsjewLPEEijPUtG3mvumyxMew04MfEHqXxWRJc9rEuTXK4cjr8wBPAPVJ2AZfYbsHnARduSecGDuXt7Mie4WoULBS2_Y63Q-li0k/s1600-h/Aileron-(XXVIII).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5286396344049388994" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 200px; CURSOR: hand; HEIGHT: 134px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNiju76d9QHp76kAjx7iFoyPC4UKpaxHyo6MS8HvODsjewLPEEijPUtG3mvumyxMew04MfEHqXxWRJc9rEuTXK4cjr8wBPAPVJ2AZfYbsHnARduSecGDuXt7Mie4WoULBS2_Y63Q-li0k/s200/Aileron-(XXVIII).jpg" border="0" /></span></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQn6kgEOc2qvjvktq3vKND5fvq3Oz6D7YvRXVYtpZpfT3ToTfAnmq43VrGj2rTQ5nkh8n4dEl-LzsxqZ1yUN3EtlTMJXQ4xxwIkoDVcwh9INtsCI70R9JXt-mUxQtlP3br-bUBveEFbDs/s1600-h/Aileron-(XXIXI).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5286431587293843570" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 200px; CURSOR: hand; HEIGHT: 134px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQn6kgEOc2qvjvktq3vKND5fvq3Oz6D7YvRXVYtpZpfT3ToTfAnmq43VrGj2rTQ5nkh8n4dEl-LzsxqZ1yUN3EtlTMJXQ4xxwIkoDVcwh9INtsCI70R9JXt-mUxQtlP3br-bUBveEFbDs/s200/Aileron-(XXIXI).jpg" border="0" /></span></a> <br /><span style="font-family:verdana;"><br /><span style="font-size:85%;"></span></span><br /><br /><br /><span style="font-family:verdana;font-size:85%;"><br /><br /><br /></span><br /><span style="font-family:verdana;font-size:85%;">The aileron will then be checked against the wing to ensure that the brackes align correctly before the aileron is put into storage. I will cover the aileron along with the rest of the aircraft after the final rigging is complete. This is probably better done without fabric on. </span><br /><div><span style="font-family:verdana;font-size:85%;"></span></div>Andy Dukehttp://www.blogger.com/profile/09382605630219566798noreply@blogger.com0tag:blogger.com,1999:blog-3930866049742766350.post-37890722034480423852008-10-05T19:26:00.004+01:002008-10-05T19:50:07.435+01:00New Door Hinges<span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;">Three pictures showing the manufacture of new door hinges. The original hinges were fixed with four small bolts to the wooden door frames. These had worked loose over time as the holes elongated so I've decided to replace the old hinges with a set that will be welded to the fuselage frame. This idea came originally from Rob Lees when he restored G-BREY.</span><br /><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJ6uUhwxvD51uOW34_h27zmNYTAcmPXaj8ZlJlFmhMRLri14U0pxdTbb5RQxQJHvM4HXvJruSN2u-AOeGb9CE4qlKicBBbI9I_HQrm7xEMWPDn1-ZTusT-oiEu7fo68Hx1gAjb4YiRAxc/s1600-h/Door-Hinge-(I).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5253740129870908306" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; CURSOR: hand" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJ6uUhwxvD51uOW34_h27zmNYTAcmPXaj8ZlJlFmhMRLri14U0pxdTbb5RQxQJHvM4HXvJruSN2u-AOeGb9CE4qlKicBBbI9I_HQrm7xEMWPDn1-ZTusT-oiEu7fo68Hx1gAjb4YiRAxc/s200/Door-Hinge-(I).jpg" border="0" /></span></a><span style="font-family:verdana;font-size:85%;">The template was made from needlework template sheet which is a fairly stiff plastic sheet marked out with a grid pattern. I was able to bend it round the original hinges which gave an acurate measurement including the 90 degree bend which would need duplicating in the new hinges. </span></p><p><span style="font-family:verdana;font-size:85%;">The hinges are made from 0.063" 4130 steel.</span></p><p><span style="font-family:Verdana;font-size:85%;"></span> </p><p><span style="font-family:verdana;font-size:85%;"></span></p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDY4d0loPFsuGa0OmGBZPmnwiR8O9ogxH67ioKxqLXxS0QeD_fDtef6KXjFja3klrDn2BfzKZF92_gXhF5jaMGe4rdJR1ZuU4vXJeCuwEol2cjBh72fKIHQRoYKLeovifUbTwKNSYv0HQ/s1600-h/Door-Hinge-(II).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5253740136640931362" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; CURSOR: hand" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDY4d0loPFsuGa0OmGBZPmnwiR8O9ogxH67ioKxqLXxS0QeD_fDtef6KXjFja3klrDn2BfzKZF92_gXhF5jaMGe4rdJR1ZuU4vXJeCuwEol2cjBh72fKIHQRoYKLeovifUbTwKNSYv0HQ/s200/Door-Hinge-(II).jpg" border="0" /></span></a></p><p><span style="font-family:verdana;font-size:85%;">The hinges after adding the 90 degree bend. </span></p><p><span style="font-family:Verdana;font-size:85%;"></span> </p><p><span style="font-family:Verdana;font-size:85%;"></span> </p><p> </p><p><span style="font-family:verdana;font-size:85%;"></span></p><p><span style="font-family:verdana;font-size:85%;"></span></p><p><span style="font-family:verdana;font-size:85%;"></span><span style="font-size:0;"></p></span><span style="font-size:0;"><p><br /></span><span style="font-family:verdana;font-size:85%;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4dkXChCyHkhofZ2IhIjEo2yb_aMcCcr20SjrXni_gYPZ_H5jtKdSATG9fsEEiTO1Q3x-f3LktRjG2Ghk7UkKI9EqTJuCDAFhrx9bo56t-szKyO8Gf2uUceBYcQMOvjwFgpRWUdnh9Wn8/s1600-h/Door-Hinge-(III).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5253740134319800210" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; CURSOR: hand" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4dkXChCyHkhofZ2IhIjEo2yb_aMcCcr20SjrXni_gYPZ_H5jtKdSATG9fsEEiTO1Q3x-f3LktRjG2Ghk7UkKI9EqTJuCDAFhrx9bo56t-szKyO8Gf2uUceBYcQMOvjwFgpRWUdnh9Wn8/s200/Door-Hinge-(III).jpg" border="0" /></span></a>Offering up the hinge</span><span style="font-family:verdana;font-size:85%;"> to check alignment with the hinge on the door. The hinge was deliberately left 'long' because it will have to be fitted to the curve in the fuselage tubing. The door and frame will be used to get an exact fit when welding although I'll use the old door frames and not the new ones when tack welding the hinges in place.<br /></span></p><span style="font-family:verdana;font-size:85%;"></span>Andy Dukehttp://www.blogger.com/profile/09382605630219566798noreply@blogger.com0tag:blogger.com,1999:blog-3930866049742766350.post-15273651822754670602008-10-05T17:44:00.005+01:002008-10-05T19:19:01.855+01:00New Door Frames<span style="font-family:verdana;font-size:85%;">Mid September and I receive an 11 foot length of 2"x8" Ash wood which will be used to replace the old door and skylight frames. I've decided to go for the door frames first as they are in some respects easier to manufacture. </span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfkxfwAgnIbYAJhgIeEqe6BeHUr-YeFtH-_h4KOBKcOkXcwpMy8Dc__585LNN3NzSpvnPANHiHmFAor4T9Gx3AwIS4SPuVxeEgvIPa3oqyLo3njjCaKSdjYItNLs5Z1gvfa-QcKNpRGjs/s1600-h/Door-Frame-(I).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5253715187379438114" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; CURSOR: hand" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfkxfwAgnIbYAJhgIeEqe6BeHUr-YeFtH-_h4KOBKcOkXcwpMy8Dc__585LNN3NzSpvnPANHiHmFAor4T9Gx3AwIS4SPuVxeEgvIPa3oqyLo3njjCaKSdjYItNLs5Z1gvfa-QcKNpRGjs/s200/Door-Frame-(I).jpg" border="0" /></span></a><span style="font-family:verdana;font-size:85%;">The first task was to cut a set of 1/2" deep blanks from which each new frame would be cut. After some head scratching we (myself and a good friend David who has an aladins cave of a workshop with all manner of equipment) managed to get 9 blanks from a single 4 foot length of Ash.</span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjsq0muMThYq_du5Spw8UuLLvd9ytlEydrYLM0-Js-Or8mJZUoQyjMkYjMweiMPvCfpHsYdck1W8MwT5v854DkoMehLkU2ESMN21QSHe3odoOjySQ0Jvf1hcqjqwtHbAwCVW5jG3GtzfEw/s1600-h/Door-Frame-(II).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5253715189417803394" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; CURSOR: hand" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjsq0muMThYq_du5Spw8UuLLvd9ytlEydrYLM0-Js-Or8mJZUoQyjMkYjMweiMPvCfpHsYdck1W8MwT5v854DkoMehLkU2ESMN21QSHe3odoOjySQ0Jvf1hcqjqwtHbAwCVW5jG3GtzfEw/s200/Door-Frame-(II).jpg" border="0" /></span></a><span style="font-family:verdana;font-size:85%;">The original frames were used as templates for the new frames, in hindsight I should have spent more time studying the old frames as there were some defects which although not serious or problematic (after all the old doors fitted OK) have to some extent been copied onto the new frames. </span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWrXcob4DXwCaj_mqh2soqxG2qr9nI4D0jew1TdwUyrqiCbExv_9z4nScQvFFtjHO-yKeVg6S0bDf_NAdX4OB2OVxl4mMkEVhT7amYBGDwkFVy-LHvh_T1uHdJ7-_J1w0hCamf4qbVEj4/s1600-h/Door-Frame-(III).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5253715200264196866" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; CURSOR: hand" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWrXcob4DXwCaj_mqh2soqxG2qr9nI4D0jew1TdwUyrqiCbExv_9z4nScQvFFtjHO-yKeVg6S0bDf_NAdX4OB2OVxl4mMkEVhT7amYBGDwkFVy-LHvh_T1uHdJ7-_J1w0hCamf4qbVEj4/s200/Door-Frame-(III).jpg" border="0" /></span></a><span style="font-family:verdana;font-size:85%;">The new frames were cut using a small band saw and jointed by hand. To provide the required strength and regidity, the frames were screwed and glued and left to cure in situ. Two pairs of hands make this job a lot easier, in this case my farther John spent two days helping.</span><br /><br /><span style="font-family:verdana;font-size:85%;"></span><br /><br /><p><span style="font-family:verdana;font-size:85%;"></span></p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjpaLC4oz4nwMZt_V0BEvJf94t4kCnJ0HhULCp5uTPDBRadfPN6H4KGavAOjZdgC0x7Y5du_8QtoO0eOqweTPIlZz0Y6haHWThD50-34Y8sDlAuP6mn8foVAnbucWhASum52wp-b-utWtU/s1600-h/Door-Frame-(IV).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5253715203906469026" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; CURSOR: hand" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjpaLC4oz4nwMZt_V0BEvJf94t4kCnJ0HhULCp5uTPDBRadfPN6H4KGavAOjZdgC0x7Y5du_8QtoO0eOqweTPIlZz0Y6haHWThD50-34Y8sDlAuP6mn8foVAnbucWhASum52wp-b-utWtU/s200/Door-Frame-(IV).jpg" border="0" /></span></a><span style="font-family:verdana;font-size:85%;">The frames still need finishing off which will include a slot for the door catch, sanding down, varnishing and final fixing although this will be left until after the fuselage is beed blasted and primed.</span></p><p><span style="font-family:Verdana;font-size:85%;"></span> </p><p><span style="font-family:Verdana;font-size:85%;"></span> </p><p><span style="font-family:Verdana;font-size:85%;"></span> </p><p><span style="font-family:verdana;font-size:85%;"></span></p><p><span style="font-family:verdana;font-size:85%;"></span></p><p><span style="font-family:verdana;font-size:85%;"></span></p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBzbHEE2-aDrPkUCCBwbA-jQR0fIVM1-NROkXdzKSZM6leBIDksaLSO7_SNyx-1iC84b7OkGsIzChWfPKlCLuBPrfWNqDJkOLVRWsnWcVa50P1xE-tywVHqDi_l69BRTLw1STxzo_vRpk/s1600-h/Door-Frame-(V).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5253715204840885586" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; CURSOR: hand" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBzbHEE2-aDrPkUCCBwbA-jQR0fIVM1-NROkXdzKSZM6leBIDksaLSO7_SNyx-1iC84b7OkGsIzChWfPKlCLuBPrfWNqDJkOLVRWsnWcVa50P1xE-tywVHqDi_l69BRTLw1STxzo_vRpk/s200/Door-Frame-(V).jpg" border="0" /></span></a></p><p><span style="font-family:verdana;font-size:85%;">The doors are slotted into the frames to check that all is well. I'm happy that the fit is snug and when finished the doors will not be draughty as long as some door seal is used.<br /></span><span style="font-family:verdana;font-size:85%;"><br /></span></p><span style="font-family:verdana;font-size:85%;"></span><br /><span style="font-family:verdana;font-size:85%;"></span><br /><br /><span style="font-family:verdana;font-size:85%;"></span><br /><br /><p><span style="font-size:0;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUFfCBj-9CJhyphenhyphenow_RHa7-6qzwlNeaQsmST72_FaQWbUrNbttZooPsS0keitThR5Bw5st8Ibsu4yYx8o1tNZkp9YM2XeNK9MVW2V7_ncghA8ZL9KCiXMTtaGC1L_YZXpo8Qk7R6IPwJ5VM/s1600-h/Door-Frame-(VII).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5253715379905579154" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; CURSOR: hand" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUFfCBj-9CJhyphenhyphenow_RHa7-6qzwlNeaQsmST72_FaQWbUrNbttZooPsS0keitThR5Bw5st8Ibsu4yYx8o1tNZkp9YM2XeNK9MVW2V7_ncghA8ZL9KCiXMTtaGC1L_YZXpo8Qk7R6IPwJ5VM/s200/Door-Frame-(VII).jpg" border="0" /></span></a></span></p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPwuLcO5veJmgxzTCim2KVfeziJ2ucqzz4nFB7YxWM0US5rrYHDNL7ak0rnxEu9_QGejf3BJIX2NTFf84_ASbm3Mvy6yDdbIZyiAzkIXf31gRy0nXNyMtppNzCXJWm6tBUVcQ2ZFilfyI/s1600-h/Door-Frame-(VI).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5253715372812244578" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; CURSOR: hand" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPwuLcO5veJmgxzTCim2KVfeziJ2ucqzz4nFB7YxWM0US5rrYHDNL7ak0rnxEu9_QGejf3BJIX2NTFf84_ASbm3Mvy6yDdbIZyiAzkIXf31gRy0nXNyMtppNzCXJWm6tBUVcQ2ZFilfyI/s200/Door-Frame-(VI).jpg" border="0" /></span></a><span style="font-family:verdana;font-size:85%;"> Not much of a gap here.</span></p><p><span style="font-family:verdana;font-size:85%;">I'm still working on the aileron and have started the metalwork for all the bits that will need welding onto the fuselage. This is because I would like to finish both ailerons (minus the covering), get various bits welded onto the fuselage and crack on with the interior before the end of the year. Next up, the door hinges.<br /></span><span style="font-family:verdana;font-size:85%;"><br /><br /></span></p><span style="font-family:verdana;font-size:85%;"></span>Andy Dukehttp://www.blogger.com/profile/09382605630219566798noreply@blogger.com0tag:blogger.com,1999:blog-3930866049742766350.post-38937329653322855892008-09-06T14:53:00.011+01:002008-09-06T16:39:28.660+01:00The Starboard Aileron - Part 2<span style="font-family:verdana;font-size:85%;">In part 1 of renovating the starboard aileron I covered the disassembly of the aileron. Now I can cover the start of the reassembly.<br /><br />Over the summer, progress was slow as I was waiting for delivery of much of the materials required for the restoration from the US. This took longer than I had originally anticipated (my advice to anyone restoring an aircraft would be to order at the earliest possible date, preferably before you start the restoration as long as you have a good idea of what will be needed). Now that everything is here I can start work again on the aileron.<br /></span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDm1zNCbH4T9WaWjQH2RQE8sCzbkJsgmDszheAvSjmm8MZ3NHpUjd6hmwJ83WML6ZNUJ8k1jEr6oaa2aqXWIWiGQle2XRJeYT6aERNPnDKa_p54uirY78AI_sgWdB4AhaszChsiXg_HtI/s1600-h/Aileron-(XIII).jpg"></a><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEirIhyUFY-VbHdX7Wng82F463YN5ajkthO8LsOV9wdP7Tlp18ezns97QjjTE8wcDHrFg4xQbNruHpnoMVHwDsVEMGqZfxEncMEMiQEfSCq0k0ejp410dCv9hTZoC7NaMbDwlVYgtlQG_G0/s1600-h/Aileron-(XVIII).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5242922501862178018" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; CURSOR: hand" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEirIhyUFY-VbHdX7Wng82F463YN5ajkthO8LsOV9wdP7Tlp18ezns97QjjTE8wcDHrFg4xQbNruHpnoMVHwDsVEMGqZfxEncMEMiQEfSCq0k0ejp410dCv9hTZoC7NaMbDwlVYgtlQG_G0/s200/Aileron-(XVIII).jpg" border="0" /></span></a><span style="font-family:verdana;font-size:85%;">The first job is to repair the crushing on the spars caused by over tightened bolts that hold the aileron hinge brackets on. You can see in this photograph how the spar has been crushed down around the bolt holes.<br /><br /><br /><br /><br /><br /><br /></span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhoxFRYiyTZIGOi2yTc2cZo0A4DABh4JyXgryjihDgcN4gPZyghibekc8VEEsa3WFS1TQMrsEiKuvF7yF6d7yofJR9L1WPYB8Nz-gh_r65l93HOGGpu7iHjp_wMhdun4Snvqv9Xpgwm3uo/s1600-h/Aileron-(XV).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5242922508166706882" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; CURSOR: hand" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhoxFRYiyTZIGOi2yTc2cZo0A4DABh4JyXgryjihDgcN4gPZyghibekc8VEEsa3WFS1TQMrsEiKuvF7yF6d7yofJR9L1WPYB8Nz-gh_r65l93HOGGpu7iHjp_wMhdun4Snvqv9Xpgwm3uo/s200/Aileron-(XV).jpg" border="0" /></span></a><span style="font-family:verdana;font-size:85%;"><br />The approved repair method is to glue a plywood patch into the recess then sand it down so that it is flush with the spar. This provides a new flat surface on which to glue the plywood doublers for the hinges.<br /><br />I arranged the plywood so that the visible grain is arranged along the length of the spar.<br /><br /><br /></span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDm1zNCbH4T9WaWjQH2RQE8sCzbkJsgmDszheAvSjmm8MZ3NHpUjd6hmwJ83WML6ZNUJ8k1jEr6oaa2aqXWIWiGQle2XRJeYT6aERNPnDKa_p54uirY78AI_sgWdB4AhaszChsiXg_HtI/s1600-h/Aileron-(XIII).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5242922707860987330" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; CURSOR: hand" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDm1zNCbH4T9WaWjQH2RQE8sCzbkJsgmDszheAvSjmm8MZ3NHpUjd6hmwJ83WML6ZNUJ8k1jEr6oaa2aqXWIWiGQle2XRJeYT6aERNPnDKa_p54uirY78AI_sgWdB4AhaszChsiXg_HtI/s200/Aileron-(XIII).jpg" border="0" /></span></a><span style="font-family:verdana;font-size:85%;"> Simple G-clamps are used to force the plywood into the recess. Aerodux adhesive was used as it is easy to apply with a small paintbrush and any excess can be wiped off with a damp cloth.<br /><br />Note: you cannot glue the doublers in place yet as this will prevent you from sliding the ribs back on.<br /><br /><br /><br /></span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5J1KqpIGbPoLs2HuhMHcfX9A8Z08CO-q2F79Qslll30XD3KHtJOohF2W2MMdv4rX1iEzsKeLbfqap7bkVbXJk1WRb90KIGwrcYlAHtO0b1BuDBNfgj0ZZQTkmUqbI6sk6JCz6C4Ftnrc/s1600-h/Aileron-(XX).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5242921924017297442" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; CURSOR: hand" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5J1KqpIGbPoLs2HuhMHcfX9A8Z08CO-q2F79Qslll30XD3KHtJOohF2W2MMdv4rX1iEzsKeLbfqap7bkVbXJk1WRb90KIGwrcYlAHtO0b1BuDBNfgj0ZZQTkmUqbI6sk6JCz6C4Ftnrc/s200/Aileron-(XX).jpg" border="0" /></span></a><span style="font-family:verdana;"><span style="font-size:85%;">All the aluminium parts were etch primed and then sprayed with an epoxy primer to provide a barrier against moisture. I have purchased a 4 stage HVLP turbine with a grvity feed gun for all the spraying. The turbine provides a separate air feed for a half face mask which is a must when spraying with most of the paint systems which can contain some very nasty chemicals. You must ensure that the turbine is located in a clean air source and that wherever you are spraying, the area is well ventilated. For most of the work at the moment I am sparying outside when conditions allow.<br /><br /><br /><br /><br /><br /><br /></span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj9FLR8jTjwWoGyDUmyPFgC9GyRiEFQNM77rYDcxNC_RdMgDBBTLQjuwPkh7RIOqFXfKG3ph7PDxKeQkfuSrCh2Z0NpPobnzCzt98J81OFKALaXLf0avCqK73ZDhc3TzPF96oD9MAzs0qE/s1600-h/Aileron-(XII).jpg"><span style="font-size:85%;"><img id="BLOGGER_PHOTO_ID_5242922707753678354" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; CURSOR: hand" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj9FLR8jTjwWoGyDUmyPFgC9GyRiEFQNM77rYDcxNC_RdMgDBBTLQjuwPkh7RIOqFXfKG3ph7PDxKeQkfuSrCh2Z0NpPobnzCzt98J81OFKALaXLf0avCqK73ZDhc3TzPF96oD9MAzs0qE/s200/Aileron-(XII).jpg" border="0" /></span></a><span style="font-size:85%;">All the ribs laid out in order (thanks to them being stamped with a locating number) prior to being slid back on to the spar. I will not nail the ribs on until I have glued the doublers on and revarnished the spar. It all seems very awkward because the ribs have to be on the spar early in the process.<br /><br /><br /><br /></span></span><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRDTvyIZsid3aUnn8wvdIBobWfW-AON55QMHV4H8Tn-SMkHOOEjLEw_grgwpjsjYm37dxvfTj6_KbwsqyNZqQsqqjjdHoOM5wjTuWzu7xU89HWmEj3pPOSyjI21b2GB3xYJ1ggMGcOOfE/s1600-h/Aileron-(XVI).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5242922503210735538" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; CURSOR: hand" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRDTvyIZsid3aUnn8wvdIBobWfW-AON55QMHV4H8Tn-SMkHOOEjLEw_grgwpjsjYm37dxvfTj6_KbwsqyNZqQsqqjjdHoOM5wjTuWzu7xU89HWmEj3pPOSyjI21b2GB3xYJ1ggMGcOOfE/s200/Aileron-(XVI).jpg" border="0" /></span></a><span style="font-family:verdana;font-size:85%;">The ribs are slid on in order (and checked against the port aileron which is still assembled).</span><span style="font-family:verdana;font-size:85%;"><br /><br /><br /><br /><br /><br /><br /><br /></span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrXJ5rPKNjqrWlwOPR8FwKVZJ6z5nv6ILWGBdQc6jOjQs4VGQTMO4A5OvUlM6mm2zxpwkLu4-hSjQstGYMrlB1PYWiA8qFCZQqKnQtCzv5ROZLiVAJJbXSHBA2FX3AXMotRvfGIYlOyr4/s1600-h/Aileron-(XVII).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5242922503462906930" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; CURSOR: hand" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrXJ5rPKNjqrWlwOPR8FwKVZJ6z5nv6ILWGBdQc6jOjQs4VGQTMO4A5OvUlM6mm2zxpwkLu4-hSjQstGYMrlB1PYWiA8qFCZQqKnQtCzv5ROZLiVAJJbXSHBA2FX3AXMotRvfGIYlOyr4/s200/Aileron-(XVII).jpg" border="0" /></span></a><span style="font-family:verdana;font-size:85%;"> I then mount the aileron in a make shift jig; two axel stands, which will be used to support the aileron while I put it back together.<br /><br /><br /><br /><br /><br /><br /><br /></span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPCSYmw0Z5bG9ZLpMeM_EBa7Ko1WuIhs53rlvyxRlMhjlSjxcn6hDa5sHhP__5qWUYAgXnCaSu9q_-fDGHOEfloOSC9KoAsN2nAiFOcjXICsZWV5Cbh246zuN-xA83Ccij5_p5oWHnG6w/s1600-h/Aileron-(XIX).jpg"><span style="font-family:verdana;font-size:85%;"><img id="BLOGGER_PHOTO_ID_5242922067339254082" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; CURSOR: hand" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPCSYmw0Z5bG9ZLpMeM_EBa7Ko1WuIhs53rlvyxRlMhjlSjxcn6hDa5sHhP__5qWUYAgXnCaSu9q_-fDGHOEfloOSC9KoAsN2nAiFOcjXICsZWV5Cbh246zuN-xA83Ccij5_p5oWHnG6w/s200/Aileron-(XIX).jpg" border="0" /></span></a><span style="font-family:verdana;font-size:85%;">I can now begin to glue the plywood doublers back on to the spar. This will take a few days as the glue requires about 24 hours to cure. As each doubler is glued into place I will need to ensure that I drill the bolt holes otherwise I end up with all the doublers in place with no clue to where the holes should be (duh!).<br /><br />I must say it feels good to see something coming back together at last although there is still a long way to go as I haven't started cleaning up the leading edge or the hinge hardware yet.<br /><br />Another job looming are the door frames as I have just received some Ash timber so time permitting I should be very busy during september.</span><span style="font-size:85%;"><span style="font-family:verdana;"><br /><br /><br /><br /></span></span><br /><br /><br /></span><div><br /><br /><span style="font-family:verdana;"></span></div><div><br /><br /><span style="font-family:verdana;font-size:85%;"></span></div><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrXJ5rPKNjqrWlwOPR8FwKVZJ6z5nv6ILWGBdQc6jOjQs4VGQTMO4A5OvUlM6mm2zxpwkLu4-hSjQstGYMrlB1PYWiA8qFCZQqKnQtCzv5ROZLiVAJJbXSHBA2FX3AXMotRvfGIYlOyr4/s1600-h/Aileron-(XVII).jpg"><span style="font-family:verdana;font-size:85%;"></span></a></div>Andy Dukehttp://www.blogger.com/profile/09382605630219566798noreply@blogger.com0tag:blogger.com,1999:blog-3930866049742766350.post-16916875385583773802008-05-18T17:03:00.010+01:002008-05-18T20:09:47.654+01:00Renovation of the Starboard Aileron<span style="font-family: verdana;font-size:85%;" >Well into May now and my shipment of hardware is only just being shipped from America mainly due to some bulky items including the new windscreen having to be back ordered. In the mean time I have sourced the etch prime and epoxy primer from Trimite in the UK so I can start to strip one of the ailerons and prep all the aluminium components so that when the American shipment is received I can put the aileron back together. <br /><br />I started by taking numerous photographs of the aileron and all it's fittings and fixtures as a reference for when I have to reassemble the aileron. I will also use the other aileron as a pattern and the wing as a jig for aligning the brackets. Next, I removed the brackets and put them to one side. Because they are visible they will be painted in the red top coat which I don't have yet so I will bead blast and paint these at a later date. <br /><br /></span><span style="font-family: verdana;font-size:85%;" ><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEinjiRlPy2sHvrWn19YiWLeXJoEwMTh91fdxgdAN6ZcNvCdD35KbxowKuGN0VajOAazKk1u2t6FuSEj1f4-phkJkm7G_JFO72MXsAWZ8xexbyzb747N1v_-xC9RBaZdQ82FyzFXU3OtJf4/s1600-h/Aileron-(I).gif"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEinjiRlPy2sHvrWn19YiWLeXJoEwMTh91fdxgdAN6ZcNvCdD35KbxowKuGN0VajOAazKk1u2t6FuSEj1f4-phkJkm7G_JFO72MXsAWZ8xexbyzb747N1v_-xC9RBaZdQ82FyzFXU3OtJf4/s200/Aileron-(I).gif" alt="" id="BLOGGER_PHOTO_ID_5201756708741809330" border="0" /></a></span><span style="font-family: verdana;font-size:85%;" ><br />The aluminium leading edge was carefully teased off and the nails removed with with a nail claw. I used a piece of aluminium sheet to protect the spar from being crushed during this delicate operation. Interestingly the aluminium was stamped as 016" 24S-T which according to a colleague of mine, was last used as a standard in </span><span style="font-family: verdana;font-size:85%;" >1929. The equivalent today is 2024T3.<br /><br /><br /></span><span style="font-family: verdana;font-size:85%;" ><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjVHnsvU5_V2GQKoGi8rkds-on4wlafOZqu6fijqnC4OpBJmcGRy5WE7tQMhct6oif398QHYeBbfdROcLeoosfrkz0l4MMhL2giH5ckkEiGn3piBcQ4zUw7tbfBy846HXmV6yUP6yAT3dI/s1600-h/Aileron-(V).gif"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjVHnsvU5_V2GQKoGi8rkds-on4wlafOZqu6fijqnC4OpBJmcGRy5WE7tQMhct6oif398QHYeBbfdROcLeoosfrkz0l4MMhL2giH5ckkEiGn3piBcQ4zUw7tbfBy846HXmV6yUP6yAT3dI/s200/Aileron-(V).gif" alt="" id="BLOGGER_PHOTO_ID_5201760002981725458" border="0" /></a></span><span style="font-family: verdana;font-size:85%;" ><br />The ribs are nailed to the spar so again each rib is teased off and the nails removed. As the ribs are removed they are stamped with a number (starting with the inboard rib) so that they will be reassembled in the same order.<br /></span><span style="font-family: verdana;font-size:85%;" ><br /><br /><br /><br /></span><span style="font-family: verdana;font-size:85%;" ><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhByklV1jIs0QE7IG7QgPu1vQUC4lmMBkkunxqDL9WH1sPf2xvm9FQM4J-7qTuOL_-5YEvDXwFvzG-WjQyh1t0TwymzyfEWOw5517wiOYyzBpBciJZsKpqe-s_EAbMJT238RtmPvcUKO7o/s1600-h/Aileron-(III).gif"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhByklV1jIs0QE7IG7QgPu1vQUC4lmMBkkunxqDL9WH1sPf2xvm9FQM4J-7qTuOL_-5YEvDXwFvzG-WjQyh1t0TwymzyfEWOw5517wiOYyzBpBciJZsKpqe-s_EAbMJT238RtmPvcUKO7o/s200/Aileron-(III).gif" alt="" id="BLOGGER_PHOTO_ID_5201759874132706530" border="0" /></a><br />With all the metal work removed from the spar, the plywood patches used to prevent the spar from splitting where the brackets are bolted through the spar, are removed. Although these were glued to the spar they came away very easily. The spar has been crushed by the bracket attachment bolts and will be repaired later.</span><span style="font-family: verdana;font-size:85%;" ><br /></span><span style="font-family: verdana;font-size:85%;" ><br /></span><span style="font-family: verdana;font-size:85%;" ><br /><br /><br /><br /><br /><br /><br /></span><span style="font-family: verdana;font-size:85%;" ><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwz3qOisjHhpH9RwodGgZIFyjYXBfOCrbj4L9T36Akv-xsjQPbsIOGiN0h88xuZptjV2qBpGR_FtRlCM99ERplA_JbJXMmHHfI035KbeoXCfUwhmHV3vPCtMWTwvrdEl5vjlGMHrTBRsE/s1600-h/Aileron-(II).gif"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwz3qOisjHhpH9RwodGgZIFyjYXBfOCrbj4L9T36Akv-xsjQPbsIOGiN0h88xuZptjV2qBpGR_FtRlCM99ERplA_JbJXMmHHfI035KbeoXCfUwhmHV3vPCtMWTwvrdEl5vjlGMHrTBRsE/s200/Aileron-(II).gif" alt="" id="BLOGGER_PHOTO_ID_5201759865542771922" border="0" /></a></span><span style="font-family: verdana;font-size:85%;" ><br />The only visible damage to the aileron is a small split at the inboard end which will have no effect on the structural strength of the spar.<br /><br /></span><span style="font-family: verdana;font-size:85%;" ><br /></span><span style="font-family: verdana;font-size:85%;" ><br /></span><span style="font-family: verdana;font-size:85%;" ><br /><br /><br /></span><span style="font-family: verdana;font-size:85%;" ><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjk-R9sc_JV0wc11LWuGDeWkfwa4GE_dJVng-H6GwFDGtmyuPrAU99l0zeSHBpltbN13GE0JrfOoI4wQ451KfcqWkufVtYdnjwNyPdlH9Ig6zzptWtKl1p0cvuTzoTrKzImPK2EBn0VBzA/s1600-h/Aileron-(IV).gif"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjk-R9sc_JV0wc11LWuGDeWkfwa4GE_dJVng-H6GwFDGtmyuPrAU99l0zeSHBpltbN13GE0JrfOoI4wQ451KfcqWkufVtYdnjwNyPdlH9Ig6zzptWtKl1p0cvuTzoTrKzImPK2EBn0VBzA/s200/Aileron-(IV).gif" alt="" id="BLOGGER_PHOTO_ID_5201759994391790850" border="0" /></a></span><span style="font-family: verdana;font-size:85%;" ><br />The spar is then rubbed down with wire wool to remove the old varnish. New plywood patches will be glued onto the spar where it has been crushed. The patches will then be sanded down flush with the spar thus filling the crushed areas. New plywood patches will then be glued on to prevent the spar wood splitting when the brackets are attached.<br /><br /><br /><br /><br /><br /><br /><br /></span><span style="font-family: verdana;font-size:85%;" ><br /></span><span style="font-family: verdana;font-size:85%;" ><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjiH5vl5iFFOr4GFDDn1f6PJwR55prOA03HW1UDTk7Ya2_AVHVtsr2_2e3r4ujjaUq9KT7_Iv__pSbXGghsRpQdBw7HqweZlGDaw-EXTo7YLVhpw5klgdXpNTthV33lFo4pOwVPbu8XhEk/s1600-h/Aileron-(VI).gif"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjiH5vl5iFFOr4GFDDn1f6PJwR55prOA03HW1UDTk7Ya2_AVHVtsr2_2e3r4ujjaUq9KT7_Iv__pSbXGghsRpQdBw7HqweZlGDaw-EXTo7YLVhpw5klgdXpNTthV33lFo4pOwVPbu8XhEk/s200/Aileron-(VI).gif" alt="" id="BLOGGER_PHOTO_ID_5201760363758978338" border="0" /></a><br />Most of the ribs needed to be stripped of old paint. This could be done by rubbing down with scotchbright or another soft non-ferrous material but I decided to do this chemically instead to save time. I'm using a paint stripper formulated specifically for removing epoxy and polyurethane paints (D23V). It came in a 25 ltr drum which I have converted into a dunk tank by removing the top then pouring water onto the surface to create a barrier as the fumes can be toxic. The ribs were then suspended in the stripper overnight.<br /><br /><br /><br /><br /><br /><br />Next day the ribs were removed from the dunk tank. The old paint literally ran off the aluminium and after washing in clean water the results are very impressive.<br /><br /></span><span style="font-family: verdana;font-size:85%;" ><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkRlWrAQx6gBRodB636BO_094HQT5HDme-07UKM40IBh1_V5T-1xl5EzzgFc7iUWRNg4i64ZvpvsiKIocXGz99Vmb7OewBOuxZvUD4j2QkA7wlLlCeXU8xn8ILilqcOgRsjgSc32GiuLk/s1600-h/Aileron-(VII).gif"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkRlWrAQx6gBRodB636BO_094HQT5HDme-07UKM40IBh1_V5T-1xl5EzzgFc7iUWRNg4i64ZvpvsiKIocXGz99Vmb7OewBOuxZvUD4j2QkA7wlLlCeXU8xn8ILilqcOgRsjgSc32GiuLk/s200/Aileron-(VII).gif" alt="" id="BLOGGER_PHOTO_ID_5201760376643880242" border="0" /></a></span><span style="font-family: verdana;font-size:85%;" ><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSmFL9D3SL6wvB7E8L-curozfRiMbJmvzVlK_pZbYJvzcMTLLpt_9h3zsVxTbxkyB7Toj0GAesovi5HSFxRe7D1qz37vFyRBNR2V9AMZtmkftTC5pHn83nY6e4HtW3Nw_T8L9JTkF_cK0/s1600-h/Aileron-(VIII).gif"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSmFL9D3SL6wvB7E8L-curozfRiMbJmvzVlK_pZbYJvzcMTLLpt_9h3zsVxTbxkyB7Toj0GAesovi5HSFxRe7D1qz37vFyRBNR2V9AMZtmkftTC5pHn83nY6e4HtW3Nw_T8L9JTkF_cK0/s200/Aileron-(VIII).gif" alt="" id="BLOGGER_PHOTO_ID_5201760385233814850" border="0" /></a></span><span style="font-size:85%;"><br /><br /><br /><br /><br /><br /><br /><br /><br /></span><span style="font-family: verdana;font-size:85%;" > <a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjeCvbD52TjjKzPI-OzXHDkxdzqCbIcB1QmFTibfjES4IT16f1D7mJK4gEJk3ceO9Uyx9XGCw2BbYHt3qLzPnpyou4Vbel7HmxsFwBcuwWJxkwBeifjegOSyZag1ZFSjMZ4lEqOY5fjhX0/s1600-h/Aileron-(IX).gif"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjeCvbD52TjjKzPI-OzXHDkxdzqCbIcB1QmFTibfjES4IT16f1D7mJK4gEJk3ceO9Uyx9XGCw2BbYHt3qLzPnpyou4Vbel7HmxsFwBcuwWJxkwBeifjegOSyZag1ZFSjMZ4lEqOY5fjhX0/s200/Aileron-(IX).gif" alt="" id="BLOGGER_PHOTO_ID_5201760574212375890" border="0" /></a></span><span style="font-size:85%;"><br /><span style="font-family: verdana;">After washing the ribs were treated with alacrom (surface treatment) to protect them. The ribs will then be painted with an etch primer and epoxy before reassembly.<br /><br />I should be receiving the wood ordered for the door and skylight frames and the floorboards soon so that will give me another job to be getting on with. At least I will soon be reassembling instead of just pulling the aircraft apart.<br /><br /><br /></span><br /><br /><br /><br /><br /><br /><br /><br /><br /></span><span style="font-family: verdana;font-size:85%;" ><br /></span><span style="font-family: verdana;font-size:85%;" > </span><span style="font-family: verdana;font-size:85%;" > </span>Andy Dukehttp://www.blogger.com/profile/09382605630219566798noreply@blogger.com1tag:blogger.com,1999:blog-3930866049742766350.post-45231115238731686392008-04-13T15:50:00.004+01:002008-04-13T16:59:53.088+01:00The Harer STC<span style="font-family: verdana;font-size:85%;" >As part of the restoration project I will be implementing the Harer STC (Supplemental Type Certificate) which will have the benefit of allowing an increase in the aircrafts all up weight from 1200 lbs to 1280 lbs. Not a great increase but in addition to a target reduction of 50 lbs to the aircrafts current weight will bring a very useful increase of 130 lbs to the usable load.<br /><br />In essence, the Harer STC calls for:<br /></span><ul style="font-family: verdana;"><li><span style="font-size:85%;">An 85 hp engine to be fitted.</span></li><li><span style="font-size:85%;">The wing attachment fittings to be strengthened.</span></li><li><span style="font-size:85%;">The lift strut attachments (at the wing) to be strengthened.</span></li><li><span style="font-size:85%;">Additional cross bracing on the fuselage.</span></li><li><span style="font-size:85%;">Provision for a larger baggage compartment.</span></li></ul><span style="font-family: verdana;font-size:85%;" >I already have the 85 hp engine and don't intend to add the larger baggage compartment as this goes against the idea of keeping the aircraft as light as possible, but the other modifications will be implemented.<br /><br />So while I await the delivery of all the hardware, paints and fabrics from the States, I decided to do as much of the airframe work, that will ultimately require welding, as soon as possible.<br /><br />The first job requires welding a diagonal bracing tube across the bottom of one of the fuselage bays. In fact two tubes are required so that they will form an X with an existing bracing tube. The first job was to work out how I could accurately cut the tube ends so that they would fit into the tube clusters and the existing bracing tube. Luckily I found a very useful web site some time ago and remembered to bookmark it for later use.<br /><br /><a href="http://www.metalgeek.com/static/cope.pcgi">http://www.metalgeek.com/static/cope.pcgi</a> provides a tube coping calculator that will give you a cutting template for joining two tubes. For the tubes I have there are various intersecting angles from 40 to 90 degrees. I've had a look at a couple of other programs for doing the same job but this one is very simple and straight forward to use.<br /><br /></span><span style="font-family: verdana;font-size:85%;" ><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6fG-8Gu1LjlrNjjeZgruWtDbfDD9aVHf9Bj8gkrAkEAS067MFpbxL6xhOIt0I73lPhCRBvYAxaTzEnVy86Vmn89sMPSLL2ioVTDmlPd_ynrz2Ep3cOD48Qwt5JwEJNfAybgtELxCTeJ0/s1600-h/Harer-I.gif"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6fG-8Gu1LjlrNjjeZgruWtDbfDD9aVHf9Bj8gkrAkEAS067MFpbxL6xhOIt0I73lPhCRBvYAxaTzEnVy86Vmn89sMPSLL2ioVTDmlPd_ynrz2Ep3cOD48Qwt5JwEJNfAybgtELxCTeJ0/s200/Harer-I.gif" alt="" id="BLOGGER_PHOTO_ID_5188742731136119554" border="0" /></a></span><span style="font-family: verdana;font-size:85%;" >Here's a sample template, downloaded in PDF format then printed and cut out ready to be wrapped around a tube.<br /></span><span style="font-family: verdana;font-size:85%;" ><br /><br /><br /><br /><br /><br /><br /></span><span style="font-family: verdana;font-size:85%;" ><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqh03fYS9L7k9NZW01W9G5OSE-dkULBYaJpz-Cf19rjZWYtgQ25QKuM-g07nGVddU_ePoxFQz014MRYoQhaA93Fa4tDclXlD_U-9STGZejulFKaAeAOdx1Tnn0BCgRurf5-nzfBJSB08w/s1600-h/Harer-II.gif"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqh03fYS9L7k9NZW01W9G5OSE-dkULBYaJpz-Cf19rjZWYtgQ25QKuM-g07nGVddU_ePoxFQz014MRYoQhaA93Fa4tDclXlD_U-9STGZejulFKaAeAOdx1Tnn0BCgRurf5-nzfBJSB08w/s200/Harer-II.gif" alt="" id="BLOGGER_PHOTO_ID_5188742735431086866" border="0" /></a></span><span style="font-size:85%;"><span style="font-family: verdana;">The Template is wrapped around the tube, which can then be cut and ground to shape. I used a dremmel for grinding.</span><br /><br /><br /><br /><br /><br /><br /><br /></span><span style="font-family: verdana;font-size:85%;" ><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjRwESb79CFABY7sHaAkJaZ2thtTGZX3Cv1Vvl_VkeEvtKBwDtk0ccqD4YkF3PsgdFYQKgrGX2hTMDLj4mrColHRHHv1mxUBGgGfCsMxPfLAYPGrlSh4dblN77f6IM6atTqxEyGgMMnTM/s1600-h/Harer-III.gif"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjRwESb79CFABY7sHaAkJaZ2thtTGZX3Cv1Vvl_VkeEvtKBwDtk0ccqD4YkF3PsgdFYQKgrGX2hTMDLj4mrColHRHHv1mxUBGgGfCsMxPfLAYPGrlSh4dblN77f6IM6atTqxEyGgMMnTM/s200/Harer-III.gif" alt="" id="BLOGGER_PHOTO_ID_5188742739726054178" border="0" /></a>A finished 90 degree intersection.<br /></span><span style="font-size:85%;"><br /></span><span style="font-family: verdana;font-size:85%;" ><br /><br /><br /><br /><br /><br /></span><span style="font-size:85%;"><br /></span><span style="font-family: verdana;font-size:85%;" ><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEim49twt9XOzgNQH0-ZKAIATZUkA1OdjE_71wZrG4iop7XJxKA7IWRKftQma9TEGzxhFP4d-CAgITKSU9nIZSBkKOsnZtR6TMvawV-7Rz76_5xvFcreErfbzS1xG24SrnWDTmiM4fOo7mY/s1600-h/Harer-IV.gif"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEim49twt9XOzgNQH0-ZKAIATZUkA1OdjE_71wZrG4iop7XJxKA7IWRKftQma9TEGzxhFP4d-CAgITKSU9nIZSBkKOsnZtR6TMvawV-7Rz76_5xvFcreErfbzS1xG24SrnWDTmiM4fOo7mY/s200/Harer-IV.gif" alt="" id="BLOGGER_PHOTO_ID_5188742744021021490" border="0" /></a></span><span style="font-size:85%;">The final join in the center of the X. This was straight forward as the intersecting angle is 90 degrees.<br /><br /><br /><br /><br /><br /><br /><br /></span><span style="font-family: verdana;font-size:85%;" ><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDOc_OAhPfGoyNVSa-1rQksgmNrYjs5oqoOobbQ9wSqPOnnMxrp9s1Hz_Ip-C82mschcliHSzujbChPr3NES2Nq4rjeQnY4UiYZc5naNQW2_KDe1dUS1N4YtiIEP6Q3CtjRW6xuG9nRw4/s1600-h/Harer-VI.gif"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDOc_OAhPfGoyNVSa-1rQksgmNrYjs5oqoOobbQ9wSqPOnnMxrp9s1Hz_Ip-C82mschcliHSzujbChPr3NES2Nq4rjeQnY4UiYZc5naNQW2_KDe1dUS1N4YtiIEP6Q3CtjRW6xuG9nRw4/s200/Harer-VI.gif" alt="" id="BLOGGER_PHOTO_ID_5188742872870040402" border="0" /></a></span><span style="font-size:85%;">The rear tube cluster showing the new bracing tube in place. Cutting this pattern is slightly more complicated as there are two horizontal tubes which intersect at different angles. I used a mashup of two templates to get the basic cutting template and then had to finish the grinding by eye plus a lot of trial fitting until I was satisfied with the result.<br /><br /><br /><br /><br /></span><span style="font-family: verdana;font-size:85%;" ><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgEPwHYelR68AfFPSg8WF4B7inq1cJq-ng3RWE29OfEo7TUyrYyq2jtgKViTs2b8vjfhybOqc68S1kHoM9GXYcDCyzypIbf28N6Sx28bI-gFBECf5hxP5liWOjsDA9cEJ3t_727OTEQN_o/s1600-h/Harer-V.gif"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgEPwHYelR68AfFPSg8WF4B7inq1cJq-ng3RWE29OfEo7TUyrYyq2jtgKViTs2b8vjfhybOqc68S1kHoM9GXYcDCyzypIbf28N6Sx28bI-gFBECf5hxP5liWOjsDA9cEJ3t_727OTEQN_o/s200/Harer-V.gif" alt="" id="BLOGGER_PHOTO_ID_5188742748315988802" border="0" /></a></span><span style="font-size:85%;">The forward tube cluster was even trickier because there are two tube sizes and different angles. Again I used two templates to get the general shape.<br /><br />The tubes will be welded in place once I have prepared all the other fittings such as door hinges, harness attachments and repairs to the rudder and horizontal stabilizers.<br /><br /><br /><br /></span>Andy Dukehttp://www.blogger.com/profile/09382605630219566798noreply@blogger.com0tag:blogger.com,1999:blog-3930866049742766350.post-35572123626660837912008-01-27T21:11:00.001+00:002009-11-07T15:43:24.532+00:00A new interior - Floorboards<span style="font-size:85%;"><span style="font-family:verdana;">I've been sidetracked so far this year with three other projects, a new car, an AD on Taylorcraft lift struts and the small matter of someone trying to build a new town on our airfield but I have at last managed to make time to start work on the aircrafts interior.</span> <span style="font-family:verdana;">The old interior was not unattractive or particularly tatty, but I feel that it could be better in a number of ways. The floor was the original aluminium which had been modified over the years and then covered with carpet. This will be replaced with a 6mm birch plywood flooring and aluminium kick plates.<br /><br /></span></span><span style="font-size:85%;"><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" style="FONT-FAMILY: verdana" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhp1mHgv2HIqgA_8fElcq5QzLfE4aAxB_4A7ox6wFWn-ZSsDxTih04ps8O4ayimz20lmj7cLbkE7PF-C1zTKzOOfHPSBqZGvHn0o_S3jio5gH5sY5_4OLfG-5Cjzs1Pc_YVIPgSCwyPoWw/s1600-h/Floorboards-(IV).jpg"><img style="MARGIN: 0pt 10px 10px 0pt; FLOAT: left; CURSOR: pointer" id="BLOGGER_PHOTO_ID_5160267346029108802" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhp1mHgv2HIqgA_8fElcq5QzLfE4aAxB_4A7ox6wFWn-ZSsDxTih04ps8O4ayimz20lmj7cLbkE7PF-C1zTKzOOfHPSBqZGvHn0o_S3jio5gH5sY5_4OLfG-5Cjzs1Pc_YVIPgSCwyPoWw/s200/Floorboards-(IV).jpg" /></a></span><span style="font-size:85%;"><span style="font-family:verdana;">Working on the principal that everything will have to be done at least twice before it works I set about creating a template floor in cheap 5.5 mm plywood first. This will then be used as the template for the final floor. </span><span style="font-family:verdana;">First the shape of the current floorboards was transferred onto the onto the plywood.<br /><br /><br /><br /><br /></span></span><span style="font-size:85%;"><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" style="FONT-FAMILY: verdana" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRQD6NWVEmAE6m6UUqVZneqoyxX9MFHYrhHFjZ5zV4DCtTL2DhM1NjqoxdB-W9eGWKSjUTzHK8jxnDhCBXKzdODCrl8lOV2Cla-2K6bG6xW939ITtpOCIjMvGhPJP8eYu9FbcrrJANuHY/s1600-h/Floorboards-(II).jpg"><img style="MARGIN: 0pt 10px 10px 0pt; FLOAT: left; CURSOR: pointer" id="BLOGGER_PHOTO_ID_5160267337439174178" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRQD6NWVEmAE6m6UUqVZneqoyxX9MFHYrhHFjZ5zV4DCtTL2DhM1NjqoxdB-W9eGWKSjUTzHK8jxnDhCBXKzdODCrl8lOV2Cla-2K6bG6xW939ITtpOCIjMvGhPJP8eYu9FbcrrJANuHY/s200/Floorboards-(II).jpg" /></a><span style="font-family:verdana;">I used a hole cutter and fly cutter to get the shape around the heel brakes. The rest of the cutting required is just straight lines at various angles.</span><br /><br /><br /><br /><br /><br /><br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" style="FONT-FAMILY: verdana" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcRJFJnYK4DaZROHBG1CGWVVA71O4UnKVPqy2C-KKxSyhu5zGOsAcuQDabhbUYA_9_WV9TiKbth7sxtbG1d_BSzLEUTgUUHQr8k1IQ8mCjbKtDQgkM4CqNC39mui-jf-7T4EFuA_BJ_ZA/s1600-h/Floorboards-(III).jpg"><img style="MARGIN: 0pt 10px 10px 0pt; FLOAT: left; CURSOR: pointer" id="BLOGGER_PHOTO_ID_5160267341734141490" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcRJFJnYK4DaZROHBG1CGWVVA71O4UnKVPqy2C-KKxSyhu5zGOsAcuQDabhbUYA_9_WV9TiKbth7sxtbG1d_BSzLEUTgUUHQr8k1IQ8mCjbKtDQgkM4CqNC39mui-jf-7T4EFuA_BJ_ZA/s200/Floorboards-(III).jpg" /></a><span style="font-family:verdana;">I used a jigsaw to cut the straight lines which meant setting up a straight edge to help guide the saw. The calipers have been set to the distance between the edge of the jigsaw footplate and the saw blade. Once set this is used for all cutting.</span><br /><br /><br /><br /><br /><br /></span><span style="font-size:85%;"><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" style="FONT-FAMILY: verdana" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiiCkuJenzcpzXC9m9GrMW8Wd5q5bdSy-lqsEJ-6vbaktFIXyU1dbk1PZiKJQBfSsLKkb3AOIwTXprucjNX5ikXZBGvSy1B4Yv5V4k0LVHhVVILL-NQC-Ms0G5Ibg1L9GhyphenhyphenXofakwMs5ro/s1600-h/Floorboards-(I).jpg"><img style="MARGIN: 0pt 10px 10px 0pt; FLOAT: left; CURSOR: pointer" id="BLOGGER_PHOTO_ID_5160267333144206866" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiiCkuJenzcpzXC9m9GrMW8Wd5q5bdSy-lqsEJ-6vbaktFIXyU1dbk1PZiKJQBfSsLKkb3AOIwTXprucjNX5ikXZBGvSy1B4Yv5V4k0LVHhVVILL-NQC-Ms0G5Ibg1L9GhyphenhyphenXofakwMs5ro/s200/Floorboards-(I).jpg" /></a><span style="font-family:verdana;">Once cut, the floorboards (which are in two halves so that they can be removed) are laid out. I will have to make some fine adjustments before I am happy with the fit, mainly because the old aluminium boards overlapped and the new plywood boards have to but up to each other. </span><span style="font-family:verdana;">This photograph shows the two floorboards in situ with work still required.<br /><br /><br /><br /></span></span><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4ey9UbZx5nUR6CeKTFxse_WWI1CAnNskUseL5ZTwapRMubpJAKbp315rhbXh68PxfQPddi3-aK8LDz92DoUQ6z-Orzfn0CY7X46-38jVnjeajaC5BcI3XgASqqYq2Rl_reSaWO4icikU/s1600-h/Floorboards-(V).jpg"><img style="MARGIN: 0pt 10px 10px 0pt; FLOAT: left; CURSOR: pointer" id="BLOGGER_PHOTO_ID_5163222176154574418" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4ey9UbZx5nUR6CeKTFxse_WWI1CAnNskUseL5ZTwapRMubpJAKbp315rhbXh68PxfQPddi3-aK8LDz92DoUQ6z-Orzfn0CY7X46-38jVnjeajaC5BcI3XgASqqYq2Rl_reSaWO4icikU/s200/Floorboards-(V).jpg" /></a><span style="font-size:85%;"><span style="font-family:verdana;">The bulkhead will slot into a grove formed by two quarter round strips of wood that will be glued in place. A battery box holding two sealed dry cell batteries will be fixed in the center of the bulkhead where it shouldn't take up too much space and will be easily accessible. It will also help fix the floor and bulkhead in place.<br /><br />I still have to manufacture the kick plates and battery box before I'm confident that I can finally make the floorboards.<br /><br /><br /></span></span>Andy Dukehttp://www.blogger.com/profile/09382605630219566798noreply@blogger.com0tag:blogger.com,1999:blog-3930866049742766350.post-19759085822134457472008-01-01T16:43:00.001+00:002008-01-01T20:44:33.554+00:00A new year and the first sign of trouble<span style="font-family: verdana;font-size:85%;" >January 1st begins pretty much as 2007 ended - foggy - so I'm back in the workshop to finish off removing fabric. All that remains are the rudder, horizontal stabilizers, elevators and undercarriage legs which shouldn't take too long.<br /><br />The undercarriage legs had been recovered a few years ago when I discovered some corrosion and had to have sleeves welded over the corrosion so I don't expect any serious issues here.<br /><br />Unfortunately as I began to strip the various components it soon became clear that there is serious corrosion in all the tail feathers and that these will all require time and effort to sort out.</span><span style="font-family: verdana;font-size:85%;" ><br /><br /><span style="font-weight: bold; color: rgb(255, 0, 0);"><span style="color: rgb(204, 0, 0);">Rudder</span><br /></span><span style="color: rgb(0, 0, 0);">The rudder was the only area where there was a visible hole in the tubing although I have not carried out a punch test on any of the other sections of corroded tubing yet. It appears that moisture must have been getting through the fabric for some considerable time but because of the thickness of the Razorback fabric it was not obvious during any of the previous 9 annual inspections.</span><span style="font-weight: bold; color: rgb(255, 0, 0);"><br /></span><br /></span><span style="font-family: verdana;font-size:85%;" ><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiG0k_hZojUQiGFsAdJnsyexFb7rq86GgMweNToKDHlMEn0WQEQLyzUFxHDc-3K9s79BjqpxmC6Ctm1HDw2uGBSYNqSOJ2R02alS8mUFOqrm-I5_LNVFBDH3jkI8m7ZvalS8dcX2QqYyoI/s1600-h/Rudder-(I).jpg"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiG0k_hZojUQiGFsAdJnsyexFb7rq86GgMweNToKDHlMEn0WQEQLyzUFxHDc-3K9s79BjqpxmC6Ctm1HDw2uGBSYNqSOJ2R02alS8mUFOqrm-I5_LNVFBDH3jkI8m7ZvalS8dcX2QqYyoI/s200/Rudder-(I).jpg" alt="" id="BLOGGER_PHOTO_ID_5150550490270810306" border="0" /></a></span><span style="font-family: verdana;font-size:85%;" ><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizjFWsCL5B5CtA9h2CpAbDlN4vb9X66tmA3XrOkLIr35Pk6xZ77lG2OetgbO0WR6iPnx-02gqndDEsiIaDjCfao6CnDQukvcm3jNZTqZHxoIhuNsWdTAZfPxhD92sCXZ7HLbjsknEsCF4/s1600-h/Rudder-(II).jpg"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizjFWsCL5B5CtA9h2CpAbDlN4vb9X66tmA3XrOkLIr35Pk6xZ77lG2OetgbO0WR6iPnx-02gqndDEsiIaDjCfao6CnDQukvcm3jNZTqZHxoIhuNsWdTAZfPxhD92sCXZ7HLbjsknEsCF4/s200/Rudder-(II).jpg" alt="" id="BLOGGER_PHOTO_ID_5150550494565777618" border="0" /></a></span><span style="font-family: verdana;font-size:85%;" ><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-nSZCY_NGqST57CivGB14PKqmR148EAUI4AjYAHiKccEAb0RuNO0FKXE_WU3fwm6BpbBxJFlWcbMDPaqVECD20x1uP2sh2vhXgeP4t8E6CbzI6qfgszuVtqr_RDOOHSG7jFqEHpeptEg/s1600-h/Rudder-(III).jpg"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-nSZCY_NGqST57CivGB14PKqmR148EAUI4AjYAHiKccEAb0RuNO0FKXE_WU3fwm6BpbBxJFlWcbMDPaqVECD20x1uP2sh2vhXgeP4t8E6CbzI6qfgszuVtqr_RDOOHSG7jFqEHpeptEg/s200/Rudder-(III).jpg" alt="" id="BLOGGER_PHOTO_ID_5150550498860744930" border="0" /></a></span><span style="font-size:85%;"><br /><br /></span><span style="font-family: verdana;font-size:85%;" ><br /><br /></span><span style="font-size:85%;"><br /></span><span style="font-family: verdana;font-size:85%;" ><br /><br /><br /><br /><span style="font-weight: bold; color: rgb(204, 0, 0);">Horizontal Stabilizers</span><br />The horizontal stabilizers are mainly corroded around the fuselage attachments which means they cannot have an internal sleeve welded inside. Note that in the second photograph the repair is to a curved tube which will be more difficult to achieve.<br /><br /></span><span style="font-family: verdana;font-size:85%;" ><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjdJiv5XcQzTQm9aAysvFY-E3_iEa7SUnl2aD8ym3rhuyGcgMbbKZmMUPV3Asc3fihfOzQ57ZDVOMOOJEvq9sPMUoTJpHUcq8zQRfUA9PqOQb1l1Cv6wVtvH8Fy3LdbctS67UjBDMsxTAI/s1600-h/Horizontal-Stabiliser-(II).jpg"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjdJiv5XcQzTQm9aAysvFY-E3_iEa7SUnl2aD8ym3rhuyGcgMbbKZmMUPV3Asc3fihfOzQ57ZDVOMOOJEvq9sPMUoTJpHUcq8zQRfUA9PqOQb1l1Cv6wVtvH8Fy3LdbctS67UjBDMsxTAI/s200/Horizontal-Stabiliser-(II).jpg" alt="" id="BLOGGER_PHOTO_ID_5150550490270810290" border="0" /></a></span><span style="font-family: verdana;font-size:85%;" ><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbqn2qJ_SGeEAMP_oKvHH_s6eIHZx4d5inTvMknjWJCAZVo7jPRW4vpdKIUYMZVjDJ1zshfe9zcPcwMqdxr4XxmIOJ93O2Y4wDlMNZWSwZNAQTDmLaRZb2cadUgwC6RshzzOCIFp0V7lE/s1600-h/Horizontal-Stabiliser-(I).jpg"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbqn2qJ_SGeEAMP_oKvHH_s6eIHZx4d5inTvMknjWJCAZVo7jPRW4vpdKIUYMZVjDJ1zshfe9zcPcwMqdxr4XxmIOJ93O2Y4wDlMNZWSwZNAQTDmLaRZb2cadUgwC6RshzzOCIFp0V7lE/s200/Horizontal-Stabiliser-(I).jpg" alt="" id="BLOGGER_PHOTO_ID_5150550159558328482" border="0" /></a></span><span style="font-size:85%;"><br /></span><span style="font-family: verdana;font-size:85%;" ><br /><br /></span><span style="font-size:85%;"><br /></span><span style="font-family: verdana;font-size:85%;" ><br /></span><span style="font-size:85%;"><br /></span><span style="font-family: verdana;font-size:85%;" ><br /><br /><br /><span style="font-weight: bold; color: rgb(204, 0, 0);">Elevators<br /></span><span style="color: rgb(0, 0, 0);">Similarly, there is a lot of corrosion around the weld clusters which will be much more difficult to repair and will probably require new U channel pieces and tube.</span><span style="font-weight: bold; color: rgb(204, 0, 0);"><br /></span></span><span style="font-family: verdana;font-size:85%;" ><br /></span><span style="font-family: verdana;font-size:85%;" ><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMB21CDEFVsTXQZyzWjZsHHrcT4ymdlUASQ5rTmogTR7Z-JYLnpL9QHldXW8DAUG3vTbvDRB0u6Mh3Q27xnY0NkiVlAuBsRbqP907giZ4CIwAS1qXpUCxVl7MLF6H_grPIAduaSW6_UiE/s1600-h/Elevator-(I).jpg"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMB21CDEFVsTXQZyzWjZsHHrcT4ymdlUASQ5rTmogTR7Z-JYLnpL9QHldXW8DAUG3vTbvDRB0u6Mh3Q27xnY0NkiVlAuBsRbqP907giZ4CIwAS1qXpUCxVl7MLF6H_grPIAduaSW6_UiE/s200/Elevator-(I).jpg" alt="" id="BLOGGER_PHOTO_ID_5150550142378459234" border="0" /></a></span><span style="font-family: verdana;font-size:85%;" ><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhfCevD63NbBxJQ6ZYzy5N1SMV1wbZsGL21G69b8W4CaZb30ugQO4q8oMHkCvlhgc-piQE3rvdZsBk99RVUFEQl_5y_PAAGDj82uYOrSpzifNy231ZTwtSHf4zc2PR-uIp6l3t0fH7sxDM/s1600-h/Elevator-(II).jpg"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhfCevD63NbBxJQ6ZYzy5N1SMV1wbZsGL21G69b8W4CaZb30ugQO4q8oMHkCvlhgc-piQE3rvdZsBk99RVUFEQl_5y_PAAGDj82uYOrSpzifNy231ZTwtSHf4zc2PR-uIp6l3t0fH7sxDM/s200/Elevator-(II).jpg" alt="" id="BLOGGER_PHOTO_ID_5150550146673426546" border="0" /></a></span><span style="font-family: verdana;font-size:85%;" ><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjv6bsWpbE2ArDr5RznMu6gfW_6XvgaiyZq8IpfTnIkThaxZmTGJYNUbAUCgQkzvrWK2hyphenhyphenv0QRQceqpiF8IjQ4EH4fartORgwiwNCDCJVGGJWAGD9jGl4m0KGHvJsETCDxj3XrQ0yAl5qk/s1600-h/Elevator-(III).jpg"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjv6bsWpbE2ArDr5RznMu6gfW_6XvgaiyZq8IpfTnIkThaxZmTGJYNUbAUCgQkzvrWK2hyphenhyphenv0QRQceqpiF8IjQ4EH4fartORgwiwNCDCJVGGJWAGD9jGl4m0KGHvJsETCDxj3XrQ0yAl5qk/s200/Elevator-(III).jpg" alt="" id="BLOGGER_PHOTO_ID_5150550150968393858" border="0" /></a></span><span style="font-size:85%;"><br /></span><span style="font-family: verdana;font-size:85%;" ><br /><br /></span><span style="font-size:85%;"><br /></span><span style="font-family: verdana;font-size:85%;" ><br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh5RwT1FCUpYVOKVIAQ53Wuy0w-M9MCpR6UsriqC063dn9B3iDzeLzlK0Nf1NyXCSHXYNzyLoPn34qBlp_lM4f0GPONjeqbl1Dubml0jIePvZJS3KcB0Uh_QDm6AhJY9OHph740Ko30nnY/s1600-h/Elevator-(IV).jpg"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh5RwT1FCUpYVOKVIAQ53Wuy0w-M9MCpR6UsriqC063dn9B3iDzeLzlK0Nf1NyXCSHXYNzyLoPn34qBlp_lM4f0GPONjeqbl1Dubml0jIePvZJS3KcB0Uh_QDm6AhJY9OHph740Ko30nnY/s200/Elevator-(IV).jpg" alt="" id="BLOGGER_PHOTO_ID_5150550155263361170" border="0" /></a><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br />With so much work to do, I will have to get approval from Carl, my inspector, for each repair method. The repairs must also conform to AC43.13-1B to ensure that structural integrity is maintained. For the moment I will try to reduce the opportunity for the corrosion to get worse while I try to figure out how to repair the damage.<br /><br />Strangely, this has not depressed me but has confirmed the need to renovate the aircraft in the first place as I now know that in places it did need it after all.<br /></span>Andy Dukehttp://www.blogger.com/profile/09382605630219566798noreply@blogger.com0tag:blogger.com,1999:blog-3930866049742766350.post-87071464767774490242007-12-24T14:40:00.000+00:002007-12-24T15:28:15.615+00:00Uncovering the Port Wing<span style="font-size:85%;"><span style="font-family: verdana;">It's almost Christmas and I've stripped the fuselage to the point that I can give it an initial inspection and satisfy myself that there are no major problems, or at least nothing that wasn't expected. so I thought it was time to check the wings out. Once I've stripped the fabric from all the major components I can put my orders in for the hardware, fabric, paints and tools that I still require knowing that I should have 90+% of all the items I require for the rebuild.</span><br /><br /><a style="font-family: verdana;" onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjIBKAZ9fe4ZDt5BU817pWa7auqBe7JrNM8oPYkkuYLR3sSx3AOkbjEKRRvv3ZBjD9X4t3NNRrdpl1XZDfwO7trGAZ1eEUU7cYIiqPnUYIE00WfFBqEYaNSI-7bAuudgwM16leje5VoxjM/s1600-h/Port-Wing-(I).jpg"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjIBKAZ9fe4ZDt5BU817pWa7auqBe7JrNM8oPYkkuYLR3sSx3AOkbjEKRRvv3ZBjD9X4t3NNRrdpl1XZDfwO7trGAZ1eEUU7cYIiqPnUYIE00WfFBqEYaNSI-7bAuudgwM16leje5VoxjM/s200/Port-Wing-(I).jpg" alt="" id="BLOGGER_PHOTO_ID_5147550947212722290" border="0" /></a><span style="font-family: verdana;">Starting with the wing leading edge, I cut the fabric so that it could be peeled back over the wing. Within two minutes I remembered that the first job should have been removing the tapes and Martin Wire clips that hold the fabric on.</span><br /><br /><span style="font-family: verdana;">Note that while removing fabric I use a mask and gloves to protect against the fiber glass and dust.<br /><br /></span><br /><a style="font-family: verdana;" onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIMj_jO5JpMPkjQa4zojkgLAGFQVElwPN0VvetMUyy3bm2E5J8ue9wtbYGyyPckTjIHi36gVSLpqEjzNS90-1V8xuzfyGoPA5zE5c_AHk2FkjLafQRG4BLNTxTLyrgm3nmUXSJSqeobR0/s1600-h/Port-Wing-(II).jpg"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIMj_jO5JpMPkjQa4zojkgLAGFQVElwPN0VvetMUyy3bm2E5J8ue9wtbYGyyPckTjIHi36gVSLpqEjzNS90-1V8xuzfyGoPA5zE5c_AHk2FkjLafQRG4BLNTxTLyrgm3nmUXSJSqeobR0/s200/Port-Wing-(II).jpg" alt="" id="BLOGGER_PHOTO_ID_5147550951507689602" border="0" /></a><span style="font-family: verdana;"><br />The tapes were easy to remove by cutting at one end using a craft knife (single edge razor blades are also good for this) then prizing the tape away from the main fabric with a screw driver to the point that I could just pull the tape off. This reveals the wire clips.</span><br /><br /><span style="font-family: verdana;">The quality of the wire clips varied from rusted or brittle to reasonably good condition although I didn't spend too much time trying to save all the wires as I have 300 feet of new stock that </span><span style="font-family: verdana;">will </span></span><span style="font-size:85%;"><a style="font-family: verdana;" onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgn8wfy1pc1sUB7YBVSWWs8ieSEU22Dq-t9p_-ynCgSpTLEAhXeM6A19fgHO0QQ-6X1mtJcINql8Z1x6ZFYWxSYsOGoOC4uJPhfz7O5zdkmFyWnUTFDzk0j_4Ah-sfcTdnmKFSqZ7sqxvs/s1600-h/Port-Wing-(III).jpg"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgn8wfy1pc1sUB7YBVSWWs8ieSEU22Dq-t9p_-ynCgSpTLEAhXeM6A19fgHO0QQ-6X1mtJcINql8Z1x6ZFYWxSYsOGoOC4uJPhfz7O5zdkmFyWnUTFDzk0j_4Ah-sfcTdnmKFSqZ7sqxvs/s200/Port-Wing-(III).jpg" alt="" id="BLOGGER_PHOTO_ID_5147550955802656914" border="0" /></a></span><span style="font-size:85%;"><span style="font-family: verdana;">be used on the wings when they are recovered.</span><br /></span><br /><span style="font-size:85%;"><br /><br /><br /><br /><br /><br /><br /><a style="font-family: verdana;" onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgtyPDYKFKwjmqXjXzODsuwxuC5N-vgGuRWu2vXb98g1oRCAYfuR64E6FH9FgZRfV_j2wkUGusasaZDEVWMfuHmA-gfLb151DsItkuZ8G4Z1wM30xTuVap3RvV37ESVQY80FQNrpd-Wwww/s1600-h/Port-Wing-(IV).jpg"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgtyPDYKFKwjmqXjXzODsuwxuC5N-vgGuRWu2vXb98g1oRCAYfuR64E6FH9FgZRfV_j2wkUGusasaZDEVWMfuHmA-gfLb151DsItkuZ8G4Z1wM30xTuVap3RvV37ESVQY80FQNrpd-Wwww/s200/Port-Wing-(IV).jpg" alt="" id="BLOGGER_PHOTO_ID_5147550960097624226" border="0" /></a><span style="font-family: verdana;">The first look inside the wing reveals that it is in very good condition with just a little surface rust on the compression tubes and drag wires but nothing to worry about.</span><br /><br /><span style="font-family: verdana;">The spars look fantastic with no apparent splitting along the scarfed and lamination joints. Luckily my Farther was a carpenter and joiner so he had a quick look and declared the spars OK although the final say will go to Carl, my inspector.<br /><br /></span><a style="font-family: verdana;" onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhc9ydF4xmIznHsNobl_Vp7X4y9X-8psrEQAEEpRx9KqQB7XuvQ6lW3AKi-aFTHEqRpyn3DVVDMwW685YoGKIafI3j9DVD2N31IHdMygMqrKzvqMDcQCWCfnlL2EnnKwhYyemNa9aX-Wvk/s1600-h/Port-Wing-(V).jpg"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhc9ydF4xmIznHsNobl_Vp7X4y9X-8psrEQAEEpRx9KqQB7XuvQ6lW3AKi-aFTHEqRpyn3DVVDMwW685YoGKIafI3j9DVD2N31IHdMygMqrKzvqMDcQCWCfnlL2EnnKwhYyemNa9aX-Wvk/s200/Port-Wing-(V).jpg" alt="" id="BLOGGER_PHOTO_ID_5147550960097624242" border="0" /></a><br /><span style="font-family: verdana;">With all the clips removed, the fabric was rolled back over the wing. The wing was turned and the process repeated on the underside.</span><br /><br /><span style="font-family: verdana;">Before starting on the next wing I will photograph each bay in turn and all the fittings. The second wing will then be stripped and photographed before I turn my attention to the ailerons and undercarriage.</span><br /><br /><br /><br /></span>Andy Dukehttp://www.blogger.com/profile/09382605630219566798noreply@blogger.com0tag:blogger.com,1999:blog-3930866049742766350.post-55417351740139102292007-12-23T11:44:00.000+00:002007-12-24T14:34:51.514+00:00Spiders Web - The Seat Support<span style="font-family: verdana;font-size:85%;" >In all the time that I have owned IH, I've never been entirely happy with the fit of the harnesses but I could never quite put my finger on what the problem was. Each annual, when inspecting the harness for wear, It would be bunched up in one corner of the triangular attachment rather than a nice even fit along one side of the triangle.<br /><br />Now that I am able to get at and remove the spiders web that is the seat support I have worked out what the problem is and I think I now know how the support should be located. So before I forget all the detail I must commit it to paper or rather html.<br /><br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2wc4aijHaxzK7AuvQYDbxQNgkgAd0yVvX3Qs23_nYsd8etEZEzlxSquf4Qt62hddn2wm1pJN8bKuXmMEMJWqHPUD5_Gbtaa7UmYotzswKhtFRinZYkI53bEhdk6v9D7_pbhBuYwJESoc/s1600-h/Seat-Support-(V).jpg"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2wc4aijHaxzK7AuvQYDbxQNgkgAd0yVvX3Qs23_nYsd8etEZEzlxSquf4Qt62hddn2wm1pJN8bKuXmMEMJWqHPUD5_Gbtaa7UmYotzswKhtFRinZYkI53bEhdk6v9D7_pbhBuYwJESoc/s200/Seat-Support-(V).jpg" alt="" id="BLOGGER_PHOTO_ID_5147135649645002850" border="0" /></a>This is the center of the cross support tube with additional straps (not standard) which have been added by a previous owner at some point. This was probably done to stop the support from sagging. Note that the two V shaped wires are held by a U clamp and the U shaped wire on the cross tube is virtually horizontal. This prevents full and free movement of the two triangular harness attachments. This as what caused my problems during each annual.<br /><br /><br />I decided that I would remove the support and assemble it on the workbench as it should be reinstalled.<br /><br /></span><span style="font-family: verdana;font-size:85%;" ><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnyhShUhy_1l0OgxBgm2KsPzzOa3pMTD1eTpfHWseE_wxQ61XMuQVP4VuDZTZCMhju7INjl6V0qIaT8gcGIKkYw6KSGJKGyNuQw2kIksEXTP4yT8ORgiIAQUmfNpFcBle8vu0GiO67GMo/s1600-h/Seat-Support-(I).jpg"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnyhShUhy_1l0OgxBgm2KsPzzOa3pMTD1eTpfHWseE_wxQ61XMuQVP4VuDZTZCMhju7INjl6V0qIaT8gcGIKkYw6KSGJKGyNuQw2kIksEXTP4yT8ORgiIAQUmfNpFcBle8vu0GiO67GMo/s200/Seat-Support-(I).jpg" alt="" id="BLOGGER_PHOTO_ID_5147134524363571234" border="0" /></a>The general layout of the support consists the cross tube, a supporting wire at each end of the cross tube and two V shaped wires (one being slightly shorter but made of a larger gauge wire, this was fixed to the rear of the support on the aircraft).<br /><br /><br /><br /><br /><br /></span><span style="font-family: verdana;font-size:85%;" ><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYMfx50329BeKnI73P1XTzEgoDP6DCRdYp8VH9ZnuAX5M6qmH70YC7MJXcWult1Psw7OxUuv_OW0mqIytz5DCV2V0ZTh3s5ESqX76a8Tiegkej9uqUaWqF4ixuzkOlOGuqWeaM1CHwt1g/s1600-h/Seat-Support-(II).jpg"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYMfx50329BeKnI73P1XTzEgoDP6DCRdYp8VH9ZnuAX5M6qmH70YC7MJXcWult1Psw7OxUuv_OW0mqIytz5DCV2V0ZTh3s5ESqX76a8Tiegkej9uqUaWqF4ixuzkOlOGuqWeaM1CHwt1g/s200/Seat-Support-(II).jpg" alt="" id="BLOGGER_PHOTO_ID_5147134528658538546" border="0" /></a>Each cross tube end has a supporting wire looped around it ensuring that the supporting wire goes through the U shaped wire welded to the tube. Note that the U shaped wire now hangs below the tube so that the harness attachment is free to move above the tube.<br /><br /></span><br /><span style="font-family: verdana;font-size:85%;" ><br /><br /><br /></span><span style="font-family: verdana;font-size:85%;" ><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjkQvEfW75qNwlLTGyRH4otoKDPmnMz4Qzso5svCtaDY6Wv48iGPKVPfHFkfuuymM-fvOXTMUTQLooX-PwLsu8eSkp2vH_rj4ImjVI2l5cstr12bZbIi30V-uCwhcHJQ9yGZ6jhprPvAFs/s1600-h/Seat-Support-(IV).jpg"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjkQvEfW75qNwlLTGyRH4otoKDPmnMz4Qzso5svCtaDY6Wv48iGPKVPfHFkfuuymM-fvOXTMUTQLooX-PwLsu8eSkp2vH_rj4ImjVI2l5cstr12bZbIi30V-uCwhcHJQ9yGZ6jhprPvAFs/s200/Seat-Support-(IV).jpg" alt="" id="BLOGGER_PHOTO_ID_5147134532953505874" border="0" /></a></span><span style="font-family: verdana;font-size:85%;" >The center of the cross tube will also have the U shaped wire now hanging below the tube. I have looped the V shaped wires through this so that they will lock in place. If anyone knows if the two V shaped wires should interlock with each other, then let me know, although I already suspect that this is the case.<br /><br />The frame will now be disassembled so that it can be straightened out a little, cleaned up and repainted.<br /><br /><br /><br /><br /><br /><br /></span>Andy Dukehttp://www.blogger.com/profile/09382605630219566798noreply@blogger.com0tag:blogger.com,1999:blog-3930866049742766350.post-3780504769169942712007-12-15T19:21:00.000+00:002007-12-24T14:36:03.435+00:00Fuel Tank and Boot Cowl<span style="font-size:85%;"><span style="font-family:verdana;">It is early December and work is progressing as quickly or as slowly as I had anticipated. The fabric is off except for the area immediately surrounding the doors, instruments and panel are out as are the seat, baggage sling and floor. The next thing I want to tackle is the main fuel tank and boot cowl and for some reason I decided to do it in that order, probably because I imagined that removing the boot cowl would be more difficult than is actually was. In hindsight remove the boot cowl first as this gives you much better access to the nuts that hold the tank in place.</span><br /><br /><span style="font-family:verdana;">Removing the tank is not difficult in itself, just disconnect all the fuel lines, undo four nuts, remove the mounting rods and hey presto, one tank removed. Of course in practice there is muck skinning of knuckles as you try to reach that inaccessible nut or your spanner slips in a confined space.</span><br /><br /><a style="font-family: verdana;" onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7T8t-T80m9jjL7fY-2ZMw_azdhYufx9lbA7uejpPLrtdwdxyotjsjrPzYJgCf_bljBbGMQM18fW99flpL1XTvG3bupaoD9PYEU1GEyKXrYb2oYZPFZ2Dav5wQg7ScbrIXaBneQ6oqxOs/s1600-h/Fuel-Tank-(I).jpg"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7T8t-T80m9jjL7fY-2ZMw_azdhYufx9lbA7uejpPLrtdwdxyotjsjrPzYJgCf_bljBbGMQM18fW99flpL1XTvG3bupaoD9PYEU1GEyKXrYb2oYZPFZ2Dav5wQg7ScbrIXaBneQ6oqxOs/s200/Fuel-Tank-(I).jpg" alt="" id="BLOGGER_PHOTO_ID_5144291058445123586" border="0" /></a><span style="font-family:verdana;">The tank is held in place by two threaded rods that pass through the tank and then through short tubes welded to the fuselage tubing. These are locked in place by nuts.</span><br /><span style="font-family:verdana;">To prevent the tank vibrating, felt is trapped between the rod and the tank (this can be seen in the picture where the rod exits the tank body.</span><br /><span style="font-family:verdana;">All four nuts are fairly easy to remove allowing the rods to be pulled through the tank body. The tank can then be lifted out from between the fuselage tubing (this would have been easier if the boot cowl had been removed already because I wouldn't have had to maneuver the filler neck through the boot cowl which required a little forceful help on the way).</span><br /><span style="font-family:verdana;"> Note that the tank should also have some felt pieces glued to the side of the tank to prevent it from vibrating against the fuselage tubing.</span><br /><a style="font-family: verdana;" onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgsuWkOLUWdHYmI5biFmYtb_OTuLSrvrxF36s_IthGVQkRvUYjvg8USmNZaubRthu5Lh8GS1xzWSkh-fuDRbMfCNz3i6cjkqgYmGSz-VB80zThDESz5QlE7vU8IIOCRXky7_l7b2JOUuL8/s1600-h/Boot-Cowl-(I).jpg"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgsuWkOLUWdHYmI5biFmYtb_OTuLSrvrxF36s_IthGVQkRvUYjvg8USmNZaubRthu5Lh8GS1xzWSkh-fuDRbMfCNz3i6cjkqgYmGSz-VB80zThDESz5QlE7vU8IIOCRXky7_l7b2JOUuL8/s200/Boot-Cowl-(I).jpg" alt="" id="BLOGGER_PHOTO_ID_5144297561025609746" border="0" /></a><a style="font-family: verdana;" onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjiT_oRZtlmo8i4RT730RJ-HAhExP6DpJYpwxFiLeLMQHkl9cRHgPS7pjEE-x22nrL3DGRavinNAzGRCBaaSHf4mOD5PJzg0Y5AObUqylPqMhbl7oxrCJuUde6fsQcocqf72s5j3vQHbmk/s1600-h/Boot-Cowl-(II).jpg"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjiT_oRZtlmo8i4RT730RJ-HAhExP6DpJYpwxFiLeLMQHkl9cRHgPS7pjEE-x22nrL3DGRavinNAzGRCBaaSHf4mOD5PJzg0Y5AObUqylPqMhbl7oxrCJuUde6fsQcocqf72s5j3vQHbmk/s200/Boot-Cowl-(II).jpg" alt="" id="BLOGGER_PHOTO_ID_5144291045560221666" border="0" /></a><span style="font-family:verdana;">The boot cowl was then tackled and this turned out to be very easy, just a matter of removing a couple of dozen screws from around the boot cowl and firewall. The boot cowl was then prized off the supporting framework revealing the tubing for the first time in decades.</span><br /><br /><a style="font-family: verdana;" onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5XrY1wOxjTkmtLqnhvNcOLsOI4_pzoOPKNSPsEdDtESLUVx4NvMA4MkuXGi63OQ1fq63qzuvvodgAbII7qIOSdruVVBCVLcO7Iy4ES6C3EysMuP-zR6LlrQvzSYiN8AXeEQ6Y529qqrw/s1600-h/Engine-Mount-(I).jpg"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5XrY1wOxjTkmtLqnhvNcOLsOI4_pzoOPKNSPsEdDtESLUVx4NvMA4MkuXGi63OQ1fq63qzuvvodgAbII7qIOSdruVVBCVLcO7Iy4ES6C3EysMuP-zR6LlrQvzSYiN8AXeEQ6Y529qqrw/s200/Engine-Mount-(I).jpg" alt="" id="BLOGGER_PHOTO_ID_5144291041265254354" border="0" /></a><span style="font-family:verdana;">This revealed the first bit of corrosion on the tubing. It looks like the paint had peeled off the tubing some time ago allowing the steel tube around the engine mount to rust. I have since used an automatic center punch to test the tube and found that it left only a small mark on the tube so I don't think the corrosion is serious although I will leave the final decision to someone with more experience in these matters than myself.<br /><br /><br /><br />This nows gives me a lot more room to work and I have since removed the 'H' frame, rudder bars, aileron pulley's and cables. These have all been bagged and tagged and put away. Although it looks as though the fuselage is stripped, there is still a lot of work to do. All the stringers need removing along with the elevator/rudder control runs and I need to clean up the tubing so that it can be visually inspected for damage/corrosion etc.<br />Then I can start on the wings.<br /></span></span>Andy Dukehttp://www.blogger.com/profile/09382605630219566798noreply@blogger.com0tag:blogger.com,1999:blog-3930866049742766350.post-56149972415859804862007-12-11T20:58:00.001+00:002007-12-11T21:57:05.456+00:00Removing the Panel and instruments<span style=";font-family:verdana;font-size:85%;" >I'm a little out of sequence with this post because removing the panel and instruments was the first thing I did having gotten the fuselage into the workshop. This was not because I felt that it was the right place to begin, but because fellow Taylorcraft owners, Martin and Mick needed to get a new panel made up for their Taylorcraft and they wanted to use mine as a template. Incidentally I intend to replace mine and already have a new blank panel waiting in the wings so to speak.<br /><br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEglBQg4gbmh9PFC6heZBdXkAGe11zShEaUQcvT6VSpoBoRMSlOIAmtxcUvwyUP6OADfwts9MH5mpURD88HlGo-xrrv55ttjUWVbY14L4zrShElXai0pqWfLWUssAnlb6xUbiVJWiPhDtmI/s1600-h/Panel-(III).jpg"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEglBQg4gbmh9PFC6heZBdXkAGe11zShEaUQcvT6VSpoBoRMSlOIAmtxcUvwyUP6OADfwts9MH5mpURD88HlGo-xrrv55ttjUWVbY14L4zrShElXai0pqWfLWUssAnlb6xUbiVJWiPhDtmI/s200/Panel-(III).jpg" alt="" id="BLOGGER_PHOTO_ID_5142823210649823426" border="0" /></a>Start by removing the yokes, this is done by disconnecting them at the 'H' frame and pulling them through the panel holes. The panel is then removed by undoing all the screws that hold the panel to the coaming, the instruments in place and finally four screws that attach the panel to the yoke mounting frames. The panel should then just pull away to be put on one side, or in this case, go off to a sheet metal basher.<br /><br /><br />This leaves a mass(or mess) of instruments dangling by various wires and pipes which were removed one at a time and put aside for later use.<br /><br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg883E1ZmY4ZgOKRn9HFnpjfeJoKQFrpJyaq76G9_QKxEXl4r-Oi0gHRbhOV4UzRSK739vodpSoh36hUE2RW-9pP4uKaWlsr9tJuyB3BFjccJunaA4vAw0LvfRTFja_zleuJz1-HkVhmvY/s1600-h/Panel-(I).jpg"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg883E1ZmY4ZgOKRn9HFnpjfeJoKQFrpJyaq76G9_QKxEXl4r-Oi0gHRbhOV4UzRSK739vodpSoh36hUE2RW-9pP4uKaWlsr9tJuyB3BFjccJunaA4vAw0LvfRTFja_zleuJz1-HkVhmvY/s200/Panel-(I).jpg" alt="" id="BLOGGER_PHOTO_ID_5142823206354856098" border="0" /></a></span><span style=";font-family:verdana;font-size:85%;" ><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEidQ6tPYFpH0O7WcV4GZRdbiPUfPj926jr_PQS4A9qftRUhxs1Jy__7TuUTXIBkJ8fK5tBmaLM5WxP2zCwTUdjVdw-MJGGchYgnn0iu39Jy_NfWYYVnFJvjpcFBfTGnKFMPyfkY9usRPcQ/s1600-h/Panel-(II).jpg"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEidQ6tPYFpH0O7WcV4GZRdbiPUfPj926jr_PQS4A9qftRUhxs1Jy__7TuUTXIBkJ8fK5tBmaLM5WxP2zCwTUdjVdw-MJGGchYgnn0iu39Jy_NfWYYVnFJvjpcFBfTGnKFMPyfkY9usRPcQ/s200/Panel-(II).jpg" alt="" id="BLOGGER_PHOTO_ID_5142823206354856114" border="0" /></a></span><span style=";font-family:verdana;font-size:85%;" ><br /><br /><br /><br /><br /><br /><br /><br /><br />Looking at the panel, you can see why it needs replacing; more holes than a Swiss cheese and a lot less tasty. The replacement panel will feature a basic triangle of instruments (ASI, tacho, altimeter, oil pressure and temperature and ignition switch) with a panel mount radio and transponder on the L/H side of the pilot's yoke. I personally like the idea of a clean panel with no glove box on the R/H side but this may change as the interior is fitted out just because it gives more storage space.<br /><br /><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmy2F1fXykC8PzhFhlMRyF1wPN9SPSQ7XaOMskJCjtwQze79xsC0ifSfiIj9wcsJTq50HDGKXk4xjozt6tlSAxl2B7ZeF5hw2x3u5J-fr1pzD0Srgp297yWMCobExFnOl4fmBBmD-PF4I/s1600-h/Panel-(IV).jpg"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmy2F1fXykC8PzhFhlMRyF1wPN9SPSQ7XaOMskJCjtwQze79xsC0ifSfiIj9wcsJTq50HDGKXk4xjozt6tlSAxl2B7ZeF5hw2x3u5J-fr1pzD0Srgp297yWMCobExFnOl4fmBBmD-PF4I/s200/Panel-(IV).jpg" alt="" id="BLOGGER_PHOTO_ID_5142823210649823442" border="0" /></a></span><span style=";font-family:verdana;font-size:85%;" ><a onblur="try {parent.deselectBloggerImageGracefully();} catch(e) {}" href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIWB12PnGp6YchtdzGwmXoIswFBGNvVg4vV_O6whmuuduJY8L1dKaEuTtB_-PVu56gDL-35JvyShyphenhyphenn-oXMY5xXyJJhOghIBm_LjSoKs3ctM0etF8eQpxh1dbhahDeFvPhQE0pnbI-BG7E/s1600-h/Panel-(V).jpg"><img style="margin: 0pt 10px 10px 0pt; float: left; cursor: pointer;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIWB12PnGp6YchtdzGwmXoIswFBGNvVg4vV_O6whmuuduJY8L1dKaEuTtB_-PVu56gDL-35JvyShyphenhyphenn-oXMY5xXyJJhOghIBm_LjSoKs3ctM0etF8eQpxh1dbhahDeFvPhQE0pnbI-BG7E/s200/Panel-(V).jpg" alt="" id="BLOGGER_PHOTO_ID_5142823214944790754" border="0" /></a></span><span style="font-size:85%;"><br /><br /></span><span style=";font-family:verdana;font-size:85%;" ><br /><br /><br /></span><span style="font-size:85%;"><br /></span><span style=";font-family:verdana;font-size:85%;" ><br /><br /><br />With the panel out of the way, the top coaming was removed to give me more room to get at the instruments and newly exposed fuel tank and fuel lines. The coaming is a heavy cardboard, and I've been told that this is original. Again this is put to one side so that it can be used as a template for an aluminum replacement.<br /><br />Interestingly, I found the following inscription penned on the side of the fuel tank<br /><br />Re-Finished (Painted)<br />"71"<br />Install 75 HP 0 time engine<br />Bert L Watermann<br />EAGIN I44<br /><br />Would this be Dahio Trotwood Airport in Dayton?<br /><br />The next job to tackle is the fuel tank, or should it be the boot cowl, or the remaining fabric or .....<br /><br /><br /></span>Andy Dukehttp://www.blogger.com/profile/09382605630219566798noreply@blogger.com0