Firestar II / Full Enclosure/ Sections

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Firestar II / Full Enclosure/ Sections

Postby planecrazzzy » Sat Dec 23, 2006 11:11 pm

Hey Guys,
              I started working on my Full Enclosure today....

I'm off work til next year ( use it or lose it )

Anyway , out in the garage using my NEW Tig machine to weld the  aluminum angle contraption.....

I had a little over 400lbs of Argon , so I figured it would get me over these next 3 days....


I got most of the nose cone piece finished....I was going to add a little

weld to radius a corner....Weld was coming out dirty......What the......

Checked my gas......said 400lbs......Hit the button.......Nothin

Ran out gas , seems the flow meter gauge that came with the Tig  machine is a little on the cheap side.....

I've got a few pictures to share.....

"My" full enclosure is going to be done in sections.....That way pieces can

be changed easy and cheaper than replacing the whole thing...

in the pictures is my Front mounting bracket for the main wind screen...

It'll have two main tubes welded to it , and doors will hinge off of them,

or Fly without the doors...

      Gotta Fly...                          
Attachments
Firestar-Fitting angle around nose cone 01.jpg
First step....I rolled Channel aluminum at work....Then after the shape was close , I cut off one of the flanges - made it an angle
Firestar-Fitting angle around nose cone 01.jpg (60.9 KiB) Viewed 12063 times
Firestar-Fitting angle around nose cone 02.jpg
Firestar-Fitting angle around nose cone 02.jpg (60.63 KiB) Viewed 12063 times
Firestar-Full Encloser Angle wrapped around nose cone 03.jpg
Firestar-Full Encloser Angle wrapped around nose cone 03.jpg (59.73 KiB) Viewed 12063 times
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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planecrazzzy
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Location: Minnesota

Full enclosure

Postby planecrazzzy » Sat Dec 23, 2006 11:16 pm

This is the outside view...

Gotta Fly...                            
Attachments
Firestar-Full Encloser -outside view of angle 04.jpg
Firestar-Full Encloser -outside view of angle 04.jpg (56.87 KiB) Viewed 12061 times
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
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Posts: 671
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

Progress

Postby planecrazzzy » Tue Dec 26, 2006 7:03 pm

I got more Argon today.....Back to work.....Hey , wait a minute , I'm on Vacation.....Back to having fun...
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  Gotta Fly...                    
Attachments
Full Enclosure - building 005.jpg
I sure LOVE my new TIG Machine
Full Enclosure - building 005.jpg (58.58 KiB) Viewed 12026 times
Full Enclosure - building 003.jpg
Full Enclosure - building 003.jpg (61.38 KiB) Viewed 12026 times
Full Enclosure - building 008.jpg
Funny angles , hard to hold - I need to make something that will hold parts for welding....(two arms & clamps)
Full Enclosure - building 008.jpg (59.57 KiB) Viewed 12026 times
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
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Posts: 671
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

Full enclosure

Postby planecrazzzy » Tue Dec 26, 2006 7:08 pm

Here's what I ended up with for today....

It's kind of got that " FLINTSTONES "  look to it....
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.
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  Gotta Fly...                        
Attachments
Full Enclosure - building 004.jpg
Full Enclosure - building 004.jpg (60.68 KiB) Viewed 12024 times
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
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Posts: 671
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

Building update

Postby planecrazzzy » Wed Dec 27, 2006 9:06 pm

I got a little more done on my Full enclosure today....Here's more pictures...
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.
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Gotta Fly...      
Attachments
Full Enclosure - building 011.jpg
I'm only 4 miles from where I work, So I took my Lexan there to use the shear....I'll be able to use the "drop" too ( 14" )
Full Enclosure - building 011.jpg (62.35 KiB) Viewed 11894 times
Full Enclosure - building 010.jpg
The rear radius is Bigger(wider).....although it's still 18" like the front....So the Lexan can be cut Square/ rectangle...
Full Enclosure - building 010.jpg (61.45 KiB) Viewed 11894 times
Full Enclosure - building 012.jpg
My Aluminum welding is "alittle" rusty...HA , get it, Rusty...Aluminum
Nevermind....
Full Enclosure - building 012.jpg (56.81 KiB) Viewed 11894 times
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
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Posts: 671
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

Building update

Postby planecrazzzy » Wed Dec 27, 2006 9:18 pm

Here's 3 more pictures of today's progress...
.
.
Gotta Fly...  
Attachments
Full Enclosure - building 018.jpg
Here's what the Main Windscreen will be attached to....(18 x 44)
The Lexan will extend past the top radius and tie into the Wing-Gap seal , probly like the Kolbra
Full Enclosure - building 018.jpg (59.47 KiB) Viewed 11892 times
Full Enclosure - building 019.jpg
Turning out square...
Full Enclosure - building 019.jpg (59.55 KiB) Viewed 11892 times
Full Enclosure - building 020.jpg
It seems to be turning out like planned....Not bad for $6 bucks worth of Aluminum so far
Full Enclosure - building 020.jpg (60.14 KiB) Viewed 11892 times
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
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Posts: 671
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

Still at it

Postby planecrazzzy » Sat Dec 30, 2006 11:33 pm

I've had a few delays....Garage heater needed a new Thermocouple the other morning.....That went straight to the TOP of the list of things to do....Lucky the weather isn't as cold as usual...
Attachments
Building Full enclosure 001.jpg
The Gap seal was put on just to get a ROUGH idea what's goin on
Building Full enclosure 001.jpg (60.35 KiB) Viewed 11723 times
Building Full enclosure 002.jpg
Building Full enclosure 002.jpg (61.09 KiB) Viewed 11723 times
Building Full enclosure 003.jpg
I wanted the windscreen to have more space....This will be capped off like the Kolbra....The piece will probly be attached to the Gap Seal
Building Full enclosure 003.jpg (60.46 KiB) Viewed 11723 times
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
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Posts: 671
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

Starting to go together now

Postby planecrazzzy » Sat Dec 30, 2006 11:45 pm

I welded up the frame....Cleaned up the welds.....Polished the tubing and shined up the rest of it....

Now I'm drilling holes ,  holding things together with Cleco's....

Tomorrow I'll trim the Lexan for a better fit and rivet to the frame ......     then bolt the frame in place.....

The other stuff that hangs off the frame will be riveted to it....
Attachments
Building Full enclosure 007.jpg
Here's the basic Frame , Welds cleaned smooth
Building Full enclosure 007.jpg (62.06 KiB) Viewed 11721 times
Building Full enclosure 012.jpg
The bungies help hold the shape
Building Full enclosure 012.jpg (59.82 KiB) Viewed 11721 times
Building Full enclosure 015.jpg
Building Full enclosure 015.jpg (61.51 KiB) Viewed 11721 times
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
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Posts: 671
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

Flyable

Postby planecrazzzy » Sun Dec 31, 2006 4:30 pm

As of this point , it's Flyable....Not done , but able to fly "as is"

I'm now working on the  Front / Sides , like the original wind screen....except , I'll be "bowing" them out for a better fit

to the doors that I'll be making....

    Gotta Fly...
                    Mike in MN
Attachments
Building Full enclosure 016.jpg
Building Full enclosure 016.jpg (60.96 KiB) Viewed 11635 times
Building Full enclosure 017.jpg
Building Full enclosure 017.jpg (59.41 KiB) Viewed 11635 times
Building Full enclosure 018.jpg
I used Aluminum rivets everywhere EXCEPT the 4 corners....There I used Stainless Steel.....The aluminum will be easy to drill out later to change the Lexan
Building Full enclosure 018.jpg (58.77 KiB) Viewed 11635 times
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
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Posts: 671
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

Front / Side pieces

Postby planecrazzzy » Sun Dec 31, 2006 4:40 pm

Here's an idea of how it's gonna look...
Attachments
Building Full enclosure 023.jpg
This will use the "Drop" from the Windscreen.....perfect...
Building Full enclosure 023.jpg (59.36 KiB) Viewed 11630 times
Building Full enclosure 021.jpg
This should give me a little more leg room , but more important , this will give me more "Stick" travel side to side.....
Building Full enclosure 021.jpg (60.41 KiB) Viewed 11630 times
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
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Posts: 671
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

Front / Side pieces

Postby planecrazzzy » Mon Jan 01, 2007 5:40 pm

I've got one of the front / side frames done....

The original windscreen bolts will hold it in place... That's why the frame only has three sides.

Gotta Fly...      
Attachments
Building Full enclosure 025.jpg
Just gotta clean it up and put on the Lexan
Building Full enclosure 025.jpg (62.32 KiB) Viewed 11448 times
Building Full enclosure 026.jpg
Building Full enclosure 026.jpg (61.67 KiB) Viewed 11448 times
Building Full enclosure 027.jpg
Frame is in place , Aluminum Flat bar wedges bettween the Lexan and the tube.
Then is held in place by the original Bolt holes ( Aluminum plate-Miss Lucky Stars )
Building Full enclosure 027.jpg (60.08 KiB) Viewed 11448 times
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
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Posts: 671
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

Pictures

Postby planecrazzzy » Tue Jan 02, 2007 7:57 pm

Here's a couple of pictures....I still need to "fit it" a little more....But it's turning out fine...
Attachments
Building Full enclosure 033.jpg
Building Full enclosure 033.jpg (60.82 KiB) Viewed 11357 times
Building Full enclosure 032.jpg
Building Full enclosure 032.jpg (60.21 KiB) Viewed 11357 times
Building Full enclosure 031.jpg
Building Full enclosure 031.jpg (59.95 KiB) Viewed 11357 times
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
Site Admin
 
Posts: 671
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

Front / Side pieces

Postby planecrazzzy » Wed Jan 03, 2007 8:06 pm

It works good ,  I have a "lip" of aluminum that wedges between the tube and the Lexan....

Then the Original windscreen bolts are used to hold it in place......it's solid.

 Gotta Fly...
Attachments
Building Full enclosure 034.jpg
Building Full enclosure 034.jpg (59.17 KiB) Viewed 11327 times
Building Full enclosure 036.jpg
Now I need to make another one on the other side...
Building Full enclosure 036.jpg (59.74 KiB) Viewed 11327 times
Building Full enclosure 037.jpg
Building Full enclosure 037.jpg (59.73 KiB) Viewed 11327 times
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
Site Admin
 
Posts: 671
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

Front / Side pieces

Postby planecrazzzy » Thu Jan 04, 2007 8:16 pm

Frame work for front right done today...

It went faster than the first one....but the lexan will still take alot to "fit"

   Gotta Fly...
Attachments
Building Full enclosure 042.jpg
Building Full enclosure 042.jpg (60.09 KiB) Viewed 11300 times
Building Full enclosure 043.jpg
Building Full enclosure 043.jpg (60.78 KiB) Viewed 11300 times
Building Full enclosure 044.jpg
Building Full enclosure 044.jpg (60.16 KiB) Viewed 11300 times
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
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Posts: 671
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

Front right side

Postby planecrazzzy » Sat Jan 06, 2007 4:10 pm

Done with the first stage of inclosing my Firestar II....

The same amount of lexan is needed to replace the old style windscreen....

I get more protection from the wind this way and it's only a couple of pounds more...

The aluminum framework is VERY LIGHT... ( Love that TIG machine )
.
.
.

  Gotta Fly...    
Attachments
Windscreen Support 007.jpg
Old windscreen used the same size lexan to make it one piece....
Windscreen Support 007.jpg (59.67 KiB) Viewed 11281 times
Building Full enclosure 045.jpg
Building Full enclosure 045.jpg (59.45 KiB) Viewed 11281 times
Building Full enclosure 046.jpg
Thier's alot more leg room and more room to move the stick too.
Building Full enclosure 046.jpg (61.38 KiB) Viewed 11281 times
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
Site Admin
 
Posts: 671
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota


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