9/20/2000 |
Today I started studying the gear
construction and installation. A flat board was found, and the 12
degree shim strips were created for the construction jig. Planning
to build them completely by the plans, but am open to options at this point
for the choice of wheels. Just don't know what to think of the wheels
that came with it. Looks suspiciously like my lawn equipment wheels. |
0 |
9/22/2000
|
Started making metal dust today instead of saw dust.
Trying my best to accurately build to the plans, I see problems in the
basic design. Assembling the parts as provided, the arc of the aft
strut member is obviously different than the forward member. It would
thus seem that there would then be a great stress applied to either the
gear or where it is mounted. I'll study on that some more tomorrow.
Otherwise, the axle assemblies were drilled and bolted together, they then
were aligned, drilled, and bolted to the front gear member.
Alignment looks good. Tomorrow will be spent here assembling the
bungee system |
3 |
9/23/2000 |
After much consideration and frustration,
it seems if the pivot point for the trailing arm of the gear strut is moved
towards the center of the fuselage by a half inch, a great portion of the
stress is removed. Before redrilling the channel for this angle,
I'll have another good long look at it. Studying this problem prevented
any further work on the gear. Didn't know I was going to get an engineering
degree with this effort!? |
1 |
9/25/2000
|
Complete reapproach to the gear problems today.
I removed the 12 degree shims in the gear construction jig, and find that
everything now falls into place!? Makes you wonder just what Mike
really planed on us doing! Problem now exists as to if it will mount
up with the fuse correctly and give the proper geometry and wheel placement.
Shock struts were also fully assembled awaiting bungee cords which will
be done in the morning. Rivets provided with the kit were initially
used for securing tubing doublers. They have all now been removed
and replaced with a higher quality rivet. Too much rattling, and
they were also not snugging down properly, playing about 1/16th of an inch.
Not good. |
2 |
9/26/2000
|
Final assembly of all gear sub parts was achieved
this morning, and operation of shock struts were checked with out the bungee
cords in place. Surprising was the small amount of movement that
the internal stop cords allow. Doesn't seem we're far from a stiff
gear system. Shock struts were taken to a friends house to have help
stretching the bungee cords. Larger washers were needed and found.
With both or best efforts we did get the bungees in place. The main
gear system (front) was then taken over to the fuselage and a fit was eye
balled. Building it square as I approached yesterday, will not work.
Back to the jig with 12 degree shims! This done, final shaping and
riveting on the AG3 parts have made the assembly ready to install for fit
on the fuselage. |
3 |
9/27/2000
|
After about an hour this morning, I was able
to put the fuselage down on the ground and roll it around on it's newly
formed landing gear. All looks good and square. At present,
I can't even get the gear bungees to budge, but I'm guessing, engine and
all, it will in the future. |
1 |
10/5/2000 |
Took the tail wheel spring and reshaped it
to fit the new tail wheel I'm mounting to the aircraft. One minor
rebend, and drilling the mount holes through the spring and mounting block.
Another job for tomorrow. |
1 |
10/9/2000 |
Finished up the tail wheel mounting.
Made a backup plate that has anchor nuts on it inside access will not be
needed to mount or remove the tail wheel. This plate also accepts
the shoulder harness cable. This will be mounted to the tail wheel
block with epoxy and screws. |
1 |
10/21/2000 |
Pulled off the axle assemblies today.
Took them to a machine shop and made new axles for them to accept the Azusa
8" wheels and brakes. Used Grade "8" bolts cut to length. That's
a lot harder material than the axles that was supplied with the kit.
Next opportunity, I'll be fitting the brake hardware, and cables. |
2 |
10/26/2000
|
Today's endeavors included assembling the
wheel, tire, and brake assemblies. These were then mounted to the
gear legs, and two pieces per leg were fashioned and bolted to the brake
assemblies to prevent their rotation. Rigging and routing of the
brake cables to follow. Having a bit of trouble finding a way to
make them work well, and have proper receptacles for the cable ends so
that they will be adjustable, and keep the outer cable housing aligned
with the cable. |
2 |
11/11/2000 |
Tail wheel was remounted today, with bushings in
place. Will need wood screws later to assure plate will not be able
to move. Shoulder harness cable was attached to this backplate temporarily |
1 |
3/15/2001 |
After base color painting on the fuselage, the Main gear
and tail wheel was reattached to the airframe. Rudder cables were
fished out from behind the fabric through holes in the fabric that been
cut from measurements made very carefully before fabric was applied to
the fuselage. Elevator pushrod was also extracted from the fabric,
and attached to the walking beam behind the pilots seat. Springs
cables and chains are being fashioned to connect the tailwheel steering
to the rudder cables. The control stick was also trimmed to a comfortable
length. A compass will be found to mount to the top. |
1 |
3/20/2001 |
Spent the available time today finishing up the Landing
gear. Checking and installing the final bolts on the hear, and cutting
out aluminum that will serve to cover the landing gear legs, for both aesthetic
structural reasons. Also being considered here is the mechanical
brake cables and their routing. |
2 |
3/21/2001 |
Applied aluminum sheet to one side of left
main gear leg. Drilled in clecoed in place the inner skin for left
mail gear leg |
1 |
3/28/2001 |
Completed shaping and applying the aluminum
sheet to the two gear legs. Boy to they feel stout now. Tailwheel
assembly was checked over, lubricated, and cotter pins applied to both
the wheel axle, and the castor pivot. At least one part is now ready
to fly! |
2 |
4/6/2001
|
Today, I lined up the tailwheel, and finally
clamped down the tail wheel steering cables to the rudder cables.
I'd say I'm committed there! I then changed course completely on
the mechanical brake system. After setting up the left brake and
trying ti from the cockpit, I didn't feel the mechanical advantage to power
the brakes, and I also felt way too much pressure being put on the rudder.
So I then designed a very simple heel brake levers that seem to be working
quite well. Lots of lever strength, and I actually feel like I can
stop the airplane heading down a hill if needed. |
5 |
4/12/2001 |
Main gear axles were trimmed to final length,
and a single hole drilled to accommodate the cotter pin. The end
of each axle was also drilled and tapped to 8/32nds. This will allow
the mounting of wheel pants someday. The right wheel brake was also
adjusted. |
1 |
9/26/2000 |
Today started the inspection and piecing together
of the flight control systems in the cockpit. Finding and trimming
up the parts as always can be a challenge. To be encouraged though,
I see that there just ain't much left in that big box the airplane came
in! |
0 |
9/27/2000
|
Pretty much finished all sub assemblies on
the flight controls today. Can't go much further until I get the
trailing spar in place to allow mounting of the walking beam for the elevator. |
2 |
9/28/2000 |
Flight control work today was mainly concentrated
on installing hinges on the rudder and elevator. To do this I created
a new blade with .040 material for my biscuit joiner and set up the machine
to allow the cut to be centered. |
1 |
9/29/2000 |
Elevator walking beam was temporarily installed
to enable further work on flight control system. Control stick was
installed with forward bearing clamped in place. Pushrod between
stick and walking beam was trimmed and installed. Aft landing gear mount
channel was removed and trimmed to prevent conflict with pushrod between
stick and walking beam. Pushrod from walking beam to elevator
was cut to length, and temporarily installed. End was plugged as
per plans, and will be finished tomorrow. |
2 |
9/30/2000 |
Elevator push rod was finished and installed
first thing this morning. Plans call for 20 to 25 degrees of travel
and I have at least 20 but just short of 25. Nice to see! Plans told
how to do the elevator end of the push rod two different ways.
(wood plug, drilled and cut to a fork, and difficult way, mounting a threaded
rod with an adjustable fork) I figured that the only thing the adjustment
would do for me would be to reset stick center. I did it the simple
way, and figure if I need an adjusting fork, I could do it at a later date
with out loosing any time or money. Rudder controls next.
Will wait for final rigging of the aircraft before I do the ailerons. |
1 |
10/10/2000 |
Spent the day working through the many working
parts of the rudder peddle system, incorporating the mechanical brakes.
Not getting too carried away here, since I'm probably going to be buying
the 8" azusa system. I don't hear much good about the garden implement
wheels that are provided with the kit. may try to rig a adapter system
to use the fisher brakes with the new wheels. Snapped a chalk line
down the side of the fuselage to represent the route of the rudder cables.
Have a few nylon fair lead assemblies that should come in nicely.
Need to permanently mount the rudder horn, to assure a good, full route
alignment for the rudder cable system. . |
3 |
10/11/2000 |
Rudder cable fairleads were created for 2
stations each side. One cable end was swaged with a shackle inside
the thimble for attachment to peddle. Other end will wait until final
installation of rudder to assure peddle positioning. |
1 |
10/14/2000 |
Additional work was done on the rudder system.
The remaining fairleads for the rudder cables were made and installed.
The left rudder cable was cut to size and finished on both ends.
An extra swage sleeve was slipped on the cable to attach the extra cable
for the steerable tailwheel. |
2 |
10/18/2000 |
The Final rudder cable was fitted and made
today. Good movement from the peddles with out restriction.
Elevator hinges were pinned with one screw, and then travel limits were
checked. Fuse ply had to be trimmed to clear for pushrod movement. |
1 |
10/26/2000 |
Installed springs behind the rudder peddles
today. Must either shorten them, or deflect them so that they do
not align with the back of the peddles and be caused to compress, thus
locking the rudder peddle travel. |
1 |
11/11/2000 |
Aileron bellcranks, and pushrods were re installed
into the wing. Holes were drilled through fuselage sides to allow
passage of pushrod from bellcrank. Slight bend in pushrod was required
to align to control stick due to the dihedral of lower wing. |
1 |
11/12/2000
|
Aileron pushrods were cut to length and threaded
rod ends were attached temporarily with a single cleco. Ailerons
were checked for range and proper motion. Rudder springs were shortened
to allow full movement with out binding. Rudder and elevator hinges
were fitted and trimmed. At this point all flight controls are fully
operational. |
1 |
11/14/2000 |
Can I say, again, that I'm finished with the
control system? Elevator nylon bearings were removed and plywood
types supplied with the kit were installed. Elevator now moves freely.
Aileron push pull tubes were finished with threaded rod ends installed.
Nylon bearings at first false rib were also installed. Operation
is smooth with out restriction. |
2 |
12/22/2000 |
Finally got around to gluing the front control
stick bearing block in place! |
1 |
4/12/2001 |
Lower left wing was hung on the fuselage today.
Aileron installation was completed with the required nuts and bolts, and
is in an airworthy configuration. |
1 |
9/30/2000
|
Looming in the dark at the edge of the plans,
was the concept of building the cabane struts. Using scrap from the
gear jig, and the 1/2" OSB from the top of the shipping crate, I quickly
built the jig as called out in the plans. The end boards had very
prominent center lines drawn so that alignment would be easily checked.
The jig was placed on the fuse and alignment checked. All ok.
Following instructions, I then started hanging pieces on them. All attach
fittings were attached also to the fuselage. They will be redrilled
later for bushing stock. I installed doubler tubing in AS3's
and 4's at the bottom ends only so The upper ends could first be cut to
length, before doublers inserted. Since the tubing is too large for
the channel stock they are being fitted into, the ends are being crushed
to proper dimensions using wood block jaws in the vise. |
2 |
10/1/2000 |
Sunday again, and not much time available,
but holding with my motto, I did something however small it was.
I spent about an hour fitting a few more cabane struts pieces. Tomorrow
ought to bring to completion the cabanes. |
1 |
10/2/2000 |
Work day. I make a bunch of aluminum
dust today. All parts, and pieces have been crafted, and drilled.
All that remains is the final drilling for 1/4" bolts on most of the fittings
and installing the bushings on the fuselage. |
4 |
10/5/2000 |
Took all the parts of the cabanes to a friends
machine shop and shaped the ends to clear the bolts in the mount channels. |
2 |
10/26/2000 |
After much pain and consideration, I have
tossed the four forward cabane strut members. Just not pleased with
the work I did clearancing them for the bolt heads. Too much material
was removed in my opinion to meet the radius test. The jig was restored
to function, and placed back on the fuselage. Upper plates were positioned,
on forward jig. I see that Gene has provided the new 1" material
for replacement instead of the old 7/8ths tubing for these forward cabanes.
I should be able to make it work. Thus far I've mounted the lower
ends of the center struts. They say that building one airplane actually
builds two. One in the scrap pile and one on the wheels!? I'm
on my way! Hope to make great progress here tomorrow. |
1 |
10/27/2000 |
All center cabane struts are now finished
. . . .again. I am happy with the work, and will now continue towards
the rigging of the wings. All work was done with hand tools, so nothing
would get beyond inspection as it was being cut. Table top, belt
sander, dremel tool, with a fiber reinforced cutting blade was used exclusively.
Only thing that remains is the bushing stock spacers between the two forward
plates. May get to them in the morning. |
2 |
10/28/2000
|
Removed the final jig part today and finished
assembly of the cabanes. Looks good and stout. Aft plate may
be a bit out of line, will have to see if a correction will be needed. |
1 |
11/8/2000
|
Today I turned my pile of wings and parts,
into a little biplane. The eight most important holes in the airframe
that hold the wings in proper incidence, and sweep, have been drilled.
I also fashioned the landing wires attaching them with their turnbuckles
to the top end. Tomorrow's task will of course be the creation of
the interplane struts, and flying wires. Well, ok, I'll probably
also repair that rib I shattered when the wing fell from it's temporary
brace!? |
4 |
11/9/2000
|
Today finished the rigging of the wings!
They are as near as I can measure true in sweep, and incidence, with final
drilling of the interplane struts complete. Remaining on this stage,
is the flying wires, and the addition of bushings to the lower wing carry
through spars, and a few doublers in the interplane tubes. Doesn't
seem like much for a full days work, but measuring a bunch of times, before
drilling the all important holes, can be quite time consuming. Interplane
doubler parts at the "V" sections, after riveted in place, were lightly
hammered to conform to the shape of the tubing. Next work period,
will be to produce the flying wires, drilling out all fittings for final
1/4" bolts, and if times permits, installing bushings into the carry through
spars. I know a bit ambitious. .. ..
You don't build and airplane alone, this is Tim Moosey that helped
me set the wings during the rigging process |
4 |
11/11/2000
|
More checking of wing alignment today.
Airplane was stood on it's nose for a good visual check of symmetry.
It looked fine. Only thing I could think of looking at that view
was to call the NTSB! Just didn't look right. Flying wire routing
was checked and as I hear with other youngsters, the aft wire will in fact
contact the leading edge. To remedy this, the aft and forward wires
will be swapped in their position. Will look kind of odd, but apparently
most of the Youngsters flying are in fact flying this way. Turnbuckles
will be located at the interplane struts, and the lower ends will be attached
to the gear channel with shackles and 1/4" bolts. |
1 |
11/13/2000
|
6 of the 8 interplane attach points were drilled
out ot 1/4 for the final bolt. The other two will require the removal
of the landing wires, so a temporary jig placement will be required.
The left Flying wire attach point at the gear was shaped and drilled.
Four new doublers had to be produced, since those provided with the kit
would not pass the edge area test. One flying wire end was swaged
to a shackle to check alignment, and fit at the gear channel. Once
I get remaining turnbuckle parts in, I should be able to finish the flying
wire installation. |
2 |
11/14/2000 |
All interplane, and cabane wing attach points
have been drilled out to 1/4" required size. Four more bolts at this
point to drill out, and they all have to do with the forward two struts
of the cabane structure. The right side flying wire attach point
at main gear was drilled and doublers installed. |
2 |
11/15/2000
|
Day for running for parts. Having changed
up the way the turnbuckles will be mounted, I retrieved four additional
cable ends for my flying wires. Left side interplane struts were
slotted to receive flying wire attachment. Flying wires were then
created for the left side. Rather awkward trying to hold the tools
while maintaining the sleeve up against the thimble. Right side interplane
strut was slotted, and lower end of flying wires fitted to thimbles and
shackles. Upper ends of flying wires will be finished in the morning,
and should take little time at all. Having everything fitted may
require a trip outside for a required photograph. |
2 |
11/16/2000
|
Finalized all flying and landing wires today.
Aircraft was then moved outside to Take pictures.
Clicking on the picture will take you to a
page of 6 pictures of the fully rigged skeleton |
1 |
12/21/2000 |
Redrilled the forward cabane struts to accommodate
the 1/4" bolts as required by the plans. Tailwheel backup plate/
shoulder harness attach plate was permanently attached with wood screws. |
1 |
3/24/2001 |
Final mounting of the Rudder hinges were made
today. The elevator was also temporarily mounted to start their hinge
attachments. Flying struts for the tail section were cut to a rough
length. |
1 |
3/25/2001 |
Four flying struts from fin to stabilizer
structure were formed. |
2 |
3/26/2001 |
Stab and fin were again checked for square.
Finding them acceptable, I made and hung the right lower flying struts. |
1 |
3/28/2001
|
All eight flying struts for the tail section
were fully assembled and checked for alignment. All found good, two
rivets were applied to each end of struts. Tail is now very solid.
All that remains at the tail is the hanging of the tail wheel steering
cables, and aluminum sheet cover to the fin/stab root area. |
1 |
4/10/2001 |
Pulled my Flying wires back out and trimmed
up the ends of the cables where they exit the nicopress sleeves.
Instead of wrapping them with tape, I made more of a tight wrap with some
small gauge safety wire. Looks good, and wont trap water. A
few of the joints at the rudder cable, and steering cable were also done. |
1 |
4/11/2001 |
Added some small fairleads to the stabilizer
struts, to prevent the tail wheel steering cables from rubbing while in
flight. This is not a problem on the ground due to the spring displacement. |
1 |
4/13/2001 |
Lower right wing was rigged with final bolts
and washers, aileron mounted and checked for travel. Right brake
was rerigged to give equal travel to left brake. I'm at a stand
still at this point. Need an engine to finish. . . . |
1 |