Final Assembly

Re: Final Assembly

Postby planecrazzzy » Tue Apr 04, 2017 8:55 am

.
After putting all the cotter pins in place on the controls...
and having a problem with them.
I went back to look at them with a microscope camera hooked to the Laptop.

Bolts go down and back is "the rule"
Cotter pins go down.

That's one reason I didn't see the real bad one...
Yes... that's a giant crack in the Right Aileron control rods cotter pin. (Scary)

I will remove these later, ALL of them.
But for now I'll leave them until after the FAA investigation into this is over.
I've put a big red tag /note by the control rods

There are more bad ones... These are samples of what they look like.
Some only have hair line crack/fractures at the bent over area.
SOME...Look ok ? I don't trust any of them.
.
Gotta Fly...
Attachments
S20170330_0075.jpg
S20170330_0075.jpg (60.56 KiB) Viewed 961 times
S20170330_0052 with arrow.jpg
S20170330_0052 with arrow.jpg (39.11 KiB) Viewed 961 times
S20170330_0022.jpg
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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Re: Final Assembly

Postby planecrazzzy » Wed Apr 05, 2017 9:12 pm

.
I put a RED TAG/SIGN on the control area.
I can't mess with it for a while.
I guess I'll work on the panel.

I have copies of the instrument faces stuck on it.
I think I'll change it.
I'm planning on doubling some of the area around the 3 inch holes
.
no pix yet
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Re: Final Assembly

Postby planecrazzzy » Fri May 05, 2017 7:04 am

Not everything is re-assemble.
I've been working on the Panel lay-out
and instrument clearance from the panel to the fuel tank.
Also keeping all the static air instruments on one side with the compass.
The electric instruments on the other side of the Transponder and Panel GPS

I was going to make small /removable sections in the panel...
But I think I'll wait on that...
I have simple instruments... and easy access.
.
I'll put some picture here once I have some holes in the panel
By the way, after working for Aircorps Aviation...I'll be cutting my instrument
holes with a die grinding carbide bit an fine tune with a file.
It's the most precise for what I have.
I bought a fly cutter... Maybe I can rough cut a smaller diameter first.
.
Gotta Fly...
JAM
Attachments
2017 (45).JPG
2017 (46).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Re: Final Assembly

Postby planecrazzzy » Sun Jun 04, 2017 7:49 pm

Getting the holes cut out takes some time...

The basic hole is done , But two of the instruments have to be custom cut for a knob and access to an adjustment screw ( Alt & VSI )

I "Fly-Cut" the hole about 1/4 inch shy.... Then used a carbide bit to get closer...
A little filing... and topped off using a big flapper wheel (40 grit)

I've drilled the mounting holes...
.
Soon I'll have something that looks like a Panel
.
.
Gotta Fly...
JAM
.
.
Attachments
2017 (62).JPG
2017 (54).JPG
2017 (51).JPG
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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Re: Final Assembly

Postby planecrazzzy » Tue Jun 20, 2017 4:47 am

Some instruments in...
and fit-up on panel cover template looking good.
Attachments
2017 (70).JPG
2017 (71)).JPG
2017 (72)).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Re: Final Assembly

Postby planecrazzzy » Tue Jul 04, 2017 8:51 pm

Fitting the 90 degree mahogany plywood...

Transferring Paper Jig marks
Attachments
2017 (89).JPG
2017 (88).JPG
2017 (86).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Re: Final Assembly

Postby planecrazzzy » Tue Jul 04, 2017 8:54 pm

Flat Black
Attachments
2017 (102).JPG
2017 (103).JPG
2017 (104).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Re: Final Assembly

Postby planecrazzzy » Sun Aug 27, 2017 6:45 pm

Fixing a print mistake...
.
I need to Weld the HS Ribs...to hold the shape as I cut off the Leading edge 3/8" tube
I'll change it to 1/2" leading edge
.
Gotta Fly...
Attachments
HS Leading edge replacement (1).JPG
HS Leading edge replacement (2).JPG
HS Leading edge replacement(3).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Re: Final Assembly

Postby planecrazzzy » Fri Sep 01, 2017 8:54 pm

.
The old tube is left on as "Stubs"...
The 1/2" tube slips over it....
I need to clean them up better , Then Tack them (MIG)
and I'll TIG weld them.
Attachments
HS leading edge fixed with bigger tube (2).JPG
HS leading edge fixed with bigger tube (3).JPG
HS leading edge fixed with bigger tube (4).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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