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PostPosted: Sat Dec 23, 2006 11:11 pm 
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Location: Minnesota
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:
File comment: 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
Firestar-Fitting angle around nose cone 01.jpg [ 60.9 KiB | Viewed 10132 times ]
Firestar-Fitting angle around nose cone 02.jpg
Firestar-Fitting angle around nose cone 02.jpg [ 60.63 KiB | Viewed 10132 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 10132 times ]

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 Post subject: Full enclosure
PostPosted: Sat Dec 23, 2006 11:16 pm 
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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 10130 times ]

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 Post subject: Progress
PostPosted: Tue Dec 26, 2006 7:03 pm 
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I got more Argon today.....Back to work.....Hey , wait a minute , I'm on Vacation.....Back to having fun...
.
.
.



  Gotta Fly...                    


Attachments:
File comment: I sure LOVE my new TIG Machine
Full Enclosure - building 005.jpg
Full Enclosure - building 005.jpg [ 58.58 KiB | Viewed 10095 times ]
Full Enclosure - building 003.jpg
Full Enclosure - building 003.jpg [ 61.38 KiB | Viewed 10095 times ]
File comment: Funny angles , hard to hold - I need to make something that will hold parts for welding....(two arms & clamps)
Full Enclosure - building 008.jpg
Full Enclosure - building 008.jpg [ 59.57 KiB | Viewed 10095 times ]

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 Post subject: Full enclosure
PostPosted: Tue Dec 26, 2006 7:08 pm 
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Here's what I ended up with for today....

It's kind of got that " FLINTSTONES "  look to it....
.
.
.
  Gotta Fly...                        


Attachments:
Full Enclosure - building 004.jpg
Full Enclosure - building 004.jpg [ 60.68 KiB | Viewed 10093 times ]

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 Post subject: Building update
PostPosted: Wed Dec 27, 2006 9:06 pm 
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I got a little more done on my Full enclosure today....Here's more pictures...
.
.
.
Gotta Fly...      


Attachments:
File comment: 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
Full Enclosure - building 011.jpg [ 62.35 KiB | Viewed 9963 times ]
File comment: 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
Full Enclosure - building 010.jpg [ 61.45 KiB | Viewed 9963 times ]
File comment: My Aluminum welding is "alittle" rusty...HA , get it, Rusty...Aluminum
Nevermind....

Full Enclosure - building 012.jpg
Full Enclosure - building 012.jpg [ 56.81 KiB | Viewed 9963 times ]

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 Post subject: Building update
PostPosted: Wed Dec 27, 2006 9:18 pm 
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Here's 3 more pictures of today's progress...
.
.
Gotta Fly...  


Attachments:
File comment: 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
Full Enclosure - building 018.jpg [ 59.47 KiB | Viewed 9961 times ]
File comment: Turning out square...
Full Enclosure - building 019.jpg
Full Enclosure - building 019.jpg [ 59.55 KiB | Viewed 9961 times ]
File comment: It seems to be turning out like planned....Not bad for $6 bucks worth of Aluminum so far
Full Enclosure - building 020.jpg
Full Enclosure - building 020.jpg [ 60.14 KiB | Viewed 9961 times ]

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 Post subject: Still at it
PostPosted: Sat Dec 30, 2006 11:33 pm 
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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:
File comment: The Gap seal was put on just to get a ROUGH idea what's goin on
Building Full enclosure 001.jpg
Building Full enclosure 001.jpg [ 60.35 KiB | Viewed 9792 times ]
Building Full enclosure 002.jpg
Building Full enclosure 002.jpg [ 61.09 KiB | Viewed 9792 times ]
File comment: 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
Building Full enclosure 003.jpg [ 60.46 KiB | Viewed 9792 times ]

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PostPosted: Sat Dec 30, 2006 11:45 pm 
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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:
File comment: Here's the basic Frame , Welds cleaned smooth
Building Full enclosure 007.jpg
Building Full enclosure 007.jpg [ 62.06 KiB | Viewed 9790 times ]
File comment: The bungies help hold the shape
Building Full enclosure 012.jpg
Building Full enclosure 012.jpg [ 59.82 KiB | Viewed 9790 times ]
Building Full enclosure 015.jpg
Building Full enclosure 015.jpg [ 61.51 KiB | Viewed 9790 times ]

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 Post subject: Flyable
PostPosted: Sun Dec 31, 2006 4:30 pm 
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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 9704 times ]
Building Full enclosure 017.jpg
Building Full enclosure 017.jpg [ 59.41 KiB | Viewed 9704 times ]
File comment: 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
Building Full enclosure 018.jpg [ 58.77 KiB | Viewed 9704 times ]

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 Post subject: Front / Side pieces
PostPosted: Sun Dec 31, 2006 4:40 pm 
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Here's an idea of how it's gonna look...


Attachments:
File comment: This will use the "Drop" from the Windscreen.....perfect...
Building Full enclosure 023.jpg
Building Full enclosure 023.jpg [ 59.36 KiB | Viewed 9699 times ]
File comment: 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
Building Full enclosure 021.jpg [ 60.41 KiB | Viewed 9699 times ]

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 Post subject: Front / Side pieces
PostPosted: Mon Jan 01, 2007 5:40 pm 
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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:
File comment: Just gotta clean it up and put on the Lexan
Building Full enclosure 025.jpg
Building Full enclosure 025.jpg [ 62.32 KiB | Viewed 9517 times ]
Building Full enclosure 026.jpg
Building Full enclosure 026.jpg [ 61.67 KiB | Viewed 9517 times ]
File comment: 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
Building Full enclosure 027.jpg [ 60.08 KiB | Viewed 9517 times ]

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 Post subject: Pictures
PostPosted: Tue Jan 02, 2007 7:57 pm 
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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 9426 times ]
Building Full enclosure 032.jpg
Building Full enclosure 032.jpg [ 60.21 KiB | Viewed 9426 times ]
Building Full enclosure 031.jpg
Building Full enclosure 031.jpg [ 59.95 KiB | Viewed 9426 times ]

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 Post subject: Front / Side pieces
PostPosted: Wed Jan 03, 2007 8:06 pm 
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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 9396 times ]
File comment: Now I need to make another one on the other side...
Building Full enclosure 036.jpg
Building Full enclosure 036.jpg [ 59.74 KiB | Viewed 9396 times ]
Building Full enclosure 037.jpg
Building Full enclosure 037.jpg [ 59.73 KiB | Viewed 9396 times ]

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 Post subject: Front / Side pieces
PostPosted: Thu Jan 04, 2007 8:16 pm 
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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 9369 times ]
Building Full enclosure 043.jpg
Building Full enclosure 043.jpg [ 60.78 KiB | Viewed 9369 times ]
Building Full enclosure 044.jpg
Building Full enclosure 044.jpg [ 60.16 KiB | Viewed 9369 times ]

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 Post subject: Front right side
PostPosted: Sat Jan 06, 2007 4:10 pm 
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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:
File comment: Old windscreen used the same size lexan to make it one piece....
Windscreen Support 007.jpg
Windscreen Support 007.jpg [ 59.67 KiB | Viewed 9350 times ]
Building Full enclosure 045.jpg
Building Full enclosure 045.jpg [ 59.45 KiB | Viewed 9350 times ]
File comment: Thier's alot more leg room and more room to move the stick too.
Building Full enclosure 046.jpg
Building Full enclosure 046.jpg [ 61.38 KiB | Viewed 9350 times ]

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