Author Topic: Build threads look fun (Read 60015 times)

Dave_Trible · « **Reply #50 on:** May 16, 2013, 07:52:48 PM »

A busy area. Here the bellcrank platforms and leading edge doublers are epoxied in.

Dave_Trible · « **Reply #51 on:** May 17, 2013, 05:12:20 PM »

Tonight I'm going to make a couple bellcranks and put on the leadouts as its nearing time to put it in. I make my cranks from 3/16" Delrin. This is a super tough self lubricating material that just doesn't wear out. It's not cheap. The sheet you see was 12"x 48" when I bought it and was something over $100.00. However this sheet will last the rest of my natural life. You will see a bellcrank pattern and the screws I'll need to attach the cutting pattern to a Delrin blank. I doubt anyone here is going to set up to manufacture Delrin cranks but I'm showing how I do this just for your interest. The blanks are hard to cut even on the scroll saw.

Dave_Trible · « **Reply #52 on:** May 17, 2013, 05:14:04 PM »

The final cut is made on the router using a diamond bit.

Dave_Trible · « **Reply #53 on:** May 17, 2013, 05:57:25 PM »

I've whacked out two Delrin blanks on the scroll saw and have screwed the pattern to the first one.

Dave_Trible · « **Reply #54 on:** May 17, 2013, 06:01:35 PM »

The router cut. Dang that's loud!!

Dave_Trible · « **Reply #55 on:** May 17, 2013, 06:15:06 PM »

Sizing the threaded aluminum bushings.

Dave_Trible · « **Reply #56 on:** May 17, 2013, 06:24:41 PM »

Drilled, bushed and ready to go.

Dave_Trible · « **Reply #57 on:** May 17, 2013, 06:33:09 PM »

Now we spool off some .027 from MBS supply to make leadouts.

Dave_Trible · « **Reply #58 on:** May 17, 2013, 06:49:45 PM »

The double loop lasso . Can only pull tighter-never loose and gives a secure backup loop should one ever break. With Delrin over 2000 flights have been logged on one airplane done as shown with ZERO visible sign of wear on crank or cable.

Dave_Trible · « **Reply #59 on:** May 17, 2013, 08:09:32 PM »

I wrap a layer with fine soft wire then CA on the under wraps..

Dave_Trible · « **Reply #60 on:** May 17, 2013, 08:11:48 PM »

I then fold back the little tail of cable, rewrap and epoxy the wrap. Now the unit is ready to be installed.

Dave_Trible · « **Reply #61 on:** May 18, 2013, 07:07:41 PM »

Slogging along here tonight I'm starting the top sheeting with the rig still nailed down. I needed to move the pins holding the trailing edge down from top to side to get them out of the way. I glued in a piece of sheet between the ribs to support the joint of the trailing edge sheet.

Dave_Trible · « **Reply #62 on:** May 18, 2013, 07:13:49 PM »

Split a sheet of 1/16" for sheeting....

Dave_Trible · « **Reply #63 on:** May 18, 2013, 07:15:17 PM »

And glueing it on with 527 since I need work time.

Dave_Trible · « **Reply #64 on:** May 18, 2013, 07:19:09 PM »

Before I put the leading edge sheeting on (this will be open bay) I need to sand a chamfer in the leading edge so I'll mark a guide line on the edge then apply clear packing tape over the ribs to protect them while I sand. It is pretty hard to sand through that tape.

Dave_Trible · « **Reply #65 on:** May 18, 2013, 07:31:33 PM »

How the chamfer looks..This shot also shows how I had to shim under the leading edge to raise the edge up. That's what the incidence meter told me to do. It tells me the wing board has warped a little and without using the meter I'd have built a twisted wing and not understood why since I'd built many good wings off this board. The meter is king!

Dave_Trible · « **Reply #66 on:** May 18, 2013, 08:07:27 PM »

I mentioned I'd be trying some new cements. The Quick Grip is strong but is a little too thick and globs. It doesn't seem to soak in and smooth out in the joint. Notice the glue on the spar joint. It foamed up a little then becomes a chewy glob. Setting this one aside.

john e. holliday · « **Reply #67 on:** May 19, 2013, 07:37:35 AM »

Thanks Dave I will mark that one off my list. Your build sequence is different I must say.

Dave_Trible · « **Reply #68 on:** May 19, 2013, 08:15:33 AM »

John that's what I've been saying about every else's building sequence for years....this morning I'm going to get all the sheeting and cap strips on the top side then set it aside to dry so I can sand and shoot a grey coat on the take-apart airplane which has been just sitting for days. Lets see how far I get. The first shot shows the center web sheet joiner for the LE sheeting and that I got the chamfer ready on the LE. Bellcrank in loosely.

Dave_Trible · « **Reply #69 on:** May 19, 2013, 09:00:35 AM »

Leading edge sheeting on using 527 for working time. I'll do the cap strips with Gorilla CA for speed and less weight.

Dave_Trible · « **Reply #70 on:** May 19, 2013, 09:20:54 AM »

I hope you can see this. This is my stripping table which is obviously multi purpose with all the dope drips and spatters. One stationary rule (rigged on pins so it can slide up to run wood under) and a second aluminum yardstick which can slide sideways but be screwed down to create whatever space I wish. Set here at 1/4" to strip out cap strips.

Dave_Trible · « **Reply #71 on:** May 19, 2013, 10:21:50 AM »

Last entry for now, the sheet and cap strips are on the top side except the center section which I'll do after the wing is done and controls inside done. Next I'll turn it over and re-nail it down a little differently to the jig, install the landing gear and such, then sheet the bottom.

Randy Powell · « **Reply #72 on:** May 19, 2013, 10:40:16 AM »

I would have bushed the leadouts, but if you are happy that it won't wear they it's less weight. I use a horseshoe end with inserts.

Dave_Trible · « **Reply #73 on:** May 19, 2013, 11:12:02 AM »

Hi Randy. If I used most anything other than Delrin I would agree. I've used these for over twenty years and (dare I say it ) my cranks have been in several other Nats and Worlds airplanes with never a failure.

Randy Powell · « **Reply #74 on:** May 19, 2013, 12:07:51 PM »

What can I say, I'm paranoid. Belt AND suspenders guy.

Dave_Trible · « **Reply #75 on:** May 19, 2013, 12:32:08 PM »

Quote from: Randy Powell on May 19, 2013, 12:07:51 PM

What can I say, I'm paranoid. Belt AND suspenders guy.

However you keep it together is fine by me Randy.

Dave_Trible · « **Reply #76 on:** May 19, 2013, 01:53:31 PM »

OK a couple more shots before I move the board off the table to work on the other plane. (took a break to run to the casino to get my daughter some chips for her birthday- the license plate on her SUV says CARDPLAYER so you get the idea. Dropped $100 on the silly bandits and came home to the safety of the workshop).
Wanted to show sanding the sheeting flush with the leading edge for the next step- spot glueing the leading edge cap on to create a ledge to lay on the trusses when I turn it over.

Dave_Trible · « **Reply #77 on:** May 19, 2013, 02:10:57 PM »

And here is is with the cap on.

Dave_Trible · « **Reply #78 on:** May 19, 2013, 08:12:44 PM »

Shot the first grey coat on the other airplane and am still standing so I'll go a couple frames. I've pulled the wing off the jig and now need to remodel it a little to flip and remount the wing. Before I put the leading edge caps on the wing I marked where the leading edge sat on the trusses. I need to trim the trusses now to clear the curvature of the airfoil. The caps will rest on what's left after I add 1/16" shims to elevate the front on pare with the trailing edge after adding the sheeting there.

Dave_Trible · « **Reply #79 on:** May 19, 2013, 08:17:21 PM »

Quickly done with the cut off wheel in the Dremel and the knife.

Dave_Trible · « **Reply #80 on:** May 19, 2013, 08:25:03 PM »

The shims from extra cap strips CAed on and ready to nail the wing down.

Dave_Trible · « **Reply #81 on:** May 19, 2013, 08:28:22 PM »

Like this..

Dave_Trible · « **Reply #82 on:** May 19, 2013, 08:39:39 PM »

Most times I simply pin the cap down on the trusses but this time I'm spot glueing it to get pins out of my way. The granite slabs weight it down till the cement dries.

Derek Barry · « **Reply #83 on:** May 20, 2013, 08:08:29 AM »

Lookin good Dave!

See you at the Nats!

Derek

Dave_Trible · « **Reply #84 on:** May 20, 2013, 08:39:39 AM »

Had a few minutes before heading to work so...Got the wing nailed down, the TE sheeting on, the LE chamfered. Now I'm using scrap balsa to fashion a pattern for plywood landing gear platforms. These have strange angles so I pattern them so not to waste the expensive ply. I heard there was only one actual supplier left who makes it. It's common for most to use removable gear. My take-apart airplanes do have removable gear for obvious reasons. I put removable gear in most everything for years until I came to the conclusion that 1. I never took it out. 2. It was 'messier' around the gear and 3. It weighs 1-2 ounces more to make it so with blocks and fasteners. Given that I'm keeping my solid wing ribs and dispensing with the removable gear. I also do use 5/32 wire gear. These birds aren't Noblers and I fly off pretty rough turf sometimes. I've bent 1/8 wire gears on washboard landings.

Dave_Trible · « **Reply #85 on:** May 21, 2013, 12:51:47 PM »

Off work today so tried to get out real early for more test flights on the newest Desperado before the wind came up. I seemed too late as the breeze was already coming up. The grass was also really deep too but the mowers were working today. Did go ahead and fly once and think the new one will trim out OK. Now I think I've got two new decent airplanes to trim and work with. That takes a little pressure off.
The take apart ship has some patching drying so I thought I'd work more on this project. This one might slow down progress some because as weather improves I'll be transitioning to more flying time and less shop time. I'm also going to push the take apart project along so it will be ready to fly before the Nats if its needed.
The place I'm starting today is to make up the landing gear and get it installed.

Dave_Trible · « **Reply #86 on:** May 21, 2013, 12:58:49 PM »

Measure it out. Recently I had a bad drawing and made the gear a little too short. Sanded the prop so decided to lengthen the gear . I had to braze on extensions right on the bird which was interesting. Not to be repeated.

Dave_Trible · « **Reply #87 on:** May 21, 2013, 03:21:22 PM »

Bending the 5/32 wire is a lot easier with the bender I made.

Dave_Trible · « **Reply #88 on:** May 21, 2013, 05:10:41 PM »

Kevin came over. Here he is working on his Ruffy.

Dave_Trible · « **Reply #89 on:** May 21, 2013, 05:12:14 PM »

Here he is using my other wire bender to do the LG for the Ruffy.

Dave_Trible · « **Reply #90 on:** May 21, 2013, 05:16:08 PM »

Wanted to show the platform and gear ready to sew with soft wire.

Dave_Trible · « **Reply #91 on:** May 21, 2013, 05:18:38 PM »

And now epoxied in.

Dave_Trible · « **Reply #92 on:** May 21, 2013, 06:14:03 PM »

Dylan's contribution to shop night at Grandpa 's.

MarcusCordeiro · « **Reply #93 on:** May 21, 2013, 07:19:26 PM »

That is a looooong nose for sure!!!

Marcus

Dave_Trible · « **Reply #94 on:** May 22, 2013, 09:40:14 AM »

Grandpa to the rescue!

Dave_Trible · « **Reply #95 on:** May 24, 2013, 06:30:31 PM »

Yaw Mon!

Dave_Trible · « **Reply #96 on:** June 08, 2013, 01:02:17 PM »

Good news- my hobby shop phoned this morning to say they got Sigment in. Going to buy em' out. Hope to get back on this build soon. Put the last clear coat on the take-apart bird this morning and may test fly it this week.

MarcusCordeiro · « **Reply #97 on:** June 08, 2013, 03:38:26 PM »

Awesome ship.
Congrats!!!!!

Marcus

Dave_Trible · « **Reply #98 on:** June 08, 2013, 06:43:06 PM »

Thanks Marcus. Never know for sure what you have till you fly it. I'm thinking Wednesday morning......

Dave_Trible · « **Reply #99 on:** June 12, 2013, 09:48:15 AM »

Well call me fickle. I've decided to fix my number one Desperado since I think it still flies best at this point. Not going to get enough flying time to really trim out the other two new ones well and get much serious practice. If need be I'll slap on the zig zag turbulators. I put carbon inside across the split top sheeting. When that dries I'll slip the gear back in. Sure wish I'd have put the plywood rib doublers in this one.