(08) Buttercup Fuselage (Mike)

(08) Buttercup Fuselage (Mike)

Postby planecrazzzy » Fri Apr 03, 2009 8:39 am

Hey Guys,
               I'm still wrapping up some painting and assembly of the wing hardware...
But I've started the next stage ....
I've ordered my Chromoly Tubing from Dillsburg Aero works in PA
They were about half price from ACS...

Here's my material list (s)....
Dillsburg added Quantity to some of my lengths because they have a 4 ft minimum.
I'm adding there quote also...but it might be hard to see...
Both lists are in the same order ( top to bottom )

  I'm picking up my tubes this morning...

Dillsburg was Prompt... next day quote..... Fast service....
I'm picking it up the SAME WEEK !!!
and almost half price from ACS ($1,500).... My total.... ( not shipping )  was  $880.00

                                                     Gotta Fly...
                                                                      Mike & "Jaz" in MN

Wow.... Total price with shipping and Tubes came to  $868.99  plus $111.74 shipping.....$980.73 total
   

.
. NOTE :  So far... I was "Short" 2 ft of   1" - .049  Should have ordered 6 ft  
....2ft Horizontal Stabilizer , 4 ft  Flap torque tube

Also "short"  3 ft of 1-1/4" X .035.... ( For Vertical and Horizontal stabilizers )

Another "Short".... 3/8 X .035   , I ordered 32 ft more ( That's a pinch extra )

Another "Short"... 1/2" X .035 need another 20 ft , Fuselage Doors

NOTE***  I screwed up #18...... It's supposed to be  1" X .058  ( Not 1-1/4" )
.
Attachments
BC material list 4130 - cropped.jpg
BC material list 4130 - cropped.jpg (129.44 KiB) Viewed 10323 times
Dillsburg Quote- cropped.jpg
Dillsburg Quote- cropped.jpg (215.83 KiB) Viewed 10323 times
Dillsburg -Shipped tubes- cropped.jpg
Dillsburg -Shipped tubes- cropped.jpg (133.04 KiB) Viewed 10323 times
Last edited by planecrazzzy on Fri Oct 23, 2009 11:34 am, edited 6 times in total.
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Tubes for Fuselage and Tail

Postby planecrazzzy » Sat Apr 04, 2009 10:54 am

Hey Guys,
              Had some extra running around to pick up my tubes... but their home now...

                                       Gotta Fly...
                                                       Mike & "Jaz" in MN

PS  Shipping length... 20 ft
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Attachments
Buttercup 4130 tubes for Fuselage and Tail.JPG
Buttercup 4130 tubes for Fuselage and Tail.JPG (122.84 KiB) Viewed 10323 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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4130Tubes

Postby planecrazzzy » Mon Apr 06, 2009 6:24 pm

Hey Guys,
                I've sorted and checked the shippment of tubing... a few dings , but not bad...

There was tape stuck to alot of the tubes...

I wiped what was stuck on the tubes with Mineral spirits.... After, I wiped all the tubes with oil...

I made racks to store the tubes out of the way...

 The garage door doesn't have to be opened to get tubes down....

Both "sides" are open....

And the shorter tubes are kept in the middle holes of the racks...

I also have good headroom...

                                                Gotta Fly...
                                                                Mike & "Jaz" in MN
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Attachments
Racks for 4130 tubes.JPG
Racks for 4130 tubes.JPG (113.12 KiB) Viewed 10312 times
Racks for 4130 tubes 02.JPG
Racks for 4130 tubes 02.JPG (124.69 KiB) Viewed 10312 times
Racks for 4130 tubes 03.JPG
Racks for 4130 tubes 03.JPG (106.72 KiB) Viewed 10312 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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Fuselage Lay out

Postby planecrazzzy » Wed Apr 29, 2009 8:31 pm

Hey Guys,
               OK... Started laying out the Fuselage sides on the Plywood...

I bought 1/4 inch plywood... I have it supported with two fold up tables.... and a few welding stools I have ( they adjust )

I ran into some problems with the measurements on the prints.... But it wasn't too bad....

  Because the plywood is thin.... I'm adding Elmers wood glue to the blocks...

     Glad to be moving on to this stage....

                                                  Gotta Fly...
                                                                  Mike & "Jaz" in MN

PS  I thought this Fuselage was going to fit in the garage a little better....It's getting BIG fast
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Attachments
Prints - Large and small 001.jpg
In this front area is where the Measurements were messed up... Some didn't add up right... Some were just wrong.... it works out...
Prints - Large and small 001.jpg (58.97 KiB) Viewed 10284 times
Fuselage Lay out 01.JPG
Fuselage Lay out 01.JPG (94.64 KiB) Viewed 10284 times
Fuselage Lay out - Blocks 01.JPG
Fuselage Lay out - Blocks 01.JPG (106.89 KiB) Viewed 10284 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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Frame Jig

Postby planecrazzzy » Thu Apr 30, 2009 7:48 pm

Hey Guys,
                I'm making the outside tubing before I finish some of the Blocks... I'm using my Tube Bender
on most of the outside tubes.... The top tube will get a small outline tube on it....So some of my radius bends
Don't hurt a thing.... In fact , the tube is stronger.... it's not spliced...

 I'm also changing the shape.... I never liked the way it looked.... I'm making it more like a Tailwind lifting body...

That should  help slow flight even more...

                                            Gotta Fly...
                                                            Mike & "Jaz" in MN
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Attachments
Frame Jig.JPG
Frame Jig.JPG (108.23 KiB) Viewed 10282 times
Frame Jig 01.JPG
Frame Jig 01.JPG (117.75 KiB) Viewed 10282 times
Frame Jig 02.JPG
Frame Jig 02.JPG (111.21 KiB) Viewed 10282 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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Fuselage

Postby planecrazzzy » Fri May 01, 2009 7:33 pm

Hey Guys,
               Here's "My" version of Buttercup Fuselage sides... I took the Kink/ Tadpole out of it....

Front section and rear section are per print ... same distance ... same Datum Line....

Just ran the tubes straight instead of all the dancing around...

At this point... I have all these tubes cut & coped for both sides.... Still a bunch to go.

                                        Gotta Fly...
                                                         Mike & "Jaz" in MN
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Attachments
Fuselage Sides -Vertical tubes coped.JPG
Fuselage Sides -Vertical tubes coped.JPG (121.41 KiB) Viewed 10275 times
Coping Tubes-Lay out 03.JPG
Coping Tubes-Lay out 03.JPG (103.86 KiB) Viewed 10275 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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Coping tubes

Postby planecrazzzy » Fri May 01, 2009 7:43 pm

Hey Guys,
               This program for coping the tubes , has been handy.... you type in the size's of the tubes...

and copy the pattern.... cut it out and wrap it around the tube after you cut it to length....

http://www.metalgeek.com/static/cope.pcgi  

To get the copes straight across from each other, I took some pictures....

The tubes are done in "two's".... So you use them together to make a straight line down the tubes....

Use that line with your coping pattern...
Attachments
Coping Tubes-Lay out 01.JPG
Coping Tubes-Lay out 01.JPG (115.89 KiB) Viewed 10274 times
Coping Tubes-lay out.JPG
Coping Tubes-lay out.JPG (90.64 KiB) Viewed 10274 times
Coping Tubes-Lay out 02.JPG
Coping Tubes-Lay out 02.JPG (110.36 KiB) Viewed 10274 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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Coping tubes

Postby planecrazzzy » Sun May 03, 2009 9:01 am

Hey Guys,
               I'm close to having all the tubes for both side frames coped...
My First tube was a sloppy fit , so I found another place to put it without wasting too much...
 The rest have been good fits.... The "tight" fits... I grind a little to leave slight movement...

Here's some Pictures
                                         Gotta Fly...
                                                         Mike & "Jaz"
Attachments
Copes 01.JPG
Copes 01.JPG (108.18 KiB) Viewed 10270 times
Copes 02.JPG
Copes 02.JPG (90.25 KiB) Viewed 10270 times
Frame Jig 04.JPG
Frame Jig 04.JPG (123.84 KiB) Viewed 10270 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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Side Frames

Postby planecrazzzy » Sun May 03, 2009 6:53 pm

Hey Guys,
               After I tacked a side frame... I got it out of the Jig and tacked the back side too....

It only took an hour to put the other one in the jig... Tack it .... and take it out....

more like 45 min...

Here's both Frames....  I'll Tack the Tail together , Then spread the frames and work on the Cabin area...
Putting the tubes in that area... and locking the frame square.... This is how Jim C does it... That's good enough for me !

                                       Gotta Fly...
                                                       Mike & "Jaz" in MN
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Attachments
Frame Jig 06 - Both Side Frames.JPG
Frame Jig 06 - Both Side Frames.JPG (120.71 KiB) Viewed 10256 times
Fuselage 02.JPG
Fuselage 02.JPG (123.53 KiB) Viewed 10256 times
Fuselage 04.JPG
Fuselage 04.JPG (137.8 KiB) Viewed 10256 times
Last edited by planecrazzzy on Tue May 05, 2009 1:39 pm, edited 2 times in total.
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: Side Frames

Postby dmagaw » Tue May 05, 2009 12:05 pm

Mike:
Just curious, did you consider making Jim Clement's modifications to your buttercup?  The angled rear door frame and the offset rear spar carrythrough?  

Dave M
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Re: Side Frames

Postby planecrazzzy » Tue May 05, 2009 1:31 pm

 
Hi Dave,
             Glad you found the place... You gotta jump hoops to see the pictures...

Any who... I haven't compared the Doors.... These seem pretty big...  The rear spar carry through... I have Jim's
Mod package with my Tailwind Prints... What I did with the Buttercup was Raise the Tube as High as it would go...
I'll gusset down to the Wing connection....
   After more is built.... and I'm sitting in it... ( making airplane noise's )... Then I'll get a better Idea if something needs
changing... I also considered extending the nose by 2 inches... I'm 6' 1"... But when I layed out the dimesions...
it looked like I have plenty of room....So I built that to print...

Another thing about the doors... I forgot to order the Square tubing for the door frame... Oh well... not a problem.
I do have some pretty cool mods of my own so far... ( Well, cool to me )

                                         Gotta Fly...
                                                         Mike & "Jaz" the Flying Dog

.PS  another thing about the rear door frame Mod.... This plane has a rear Lift strut in that area... I don't think I would
want to mess with that area with out consulting an engineer...

.


dmagaw wrote:Mike:
Just curious, did you consider making Jim Clement's modifications to your buttercup?  The angled rear door frame and the offset rear spar carrythrough?  

Dave M
Attachments
Fuselage 05.JPG
Fuselage 05.JPG (121.97 KiB) Viewed 10258 times
Fuselage 06.JPG
Fuselage 06.JPG (126.92 KiB) Viewed 10258 times
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Fuselage Locked in square

Postby planecrazzzy » Wed May 06, 2009 8:38 pm

Hey Guys...
                 Took extra care to this point... Could have gotten out of square pretty easy...

Now... Things are "Locked in" a little better.... Still have to be careful... especialy during welding...

Getting it square is one thing.... Keeping it square is another...

 I took some pictures at funny angles to help me get a good look at square...

Some of the camera angles aren't straight ... but there close enough to see what I want...

                                            Gotta Fly...
                                                            Mike & "Jaz" in MN
Attachments
Fuselage 11.JPG
Fuselage 11.JPG (125.49 KiB) Viewed 10252 times
Fuselage 12.JPG
Fuselage 12.JPG (128.01 KiB) Viewed 10252 times
Fuselage 13.JPG
Fuselage 13.JPG (125.59 KiB) Viewed 10252 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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Front engine Bushings

Postby planecrazzzy » Tue May 12, 2009 9:01 am

Hey Guys,
               I'm ready to set this up on stands ...so it rotates...
I need to put in the front engine mount bushings... I had to take out the diagnal tube.
Then , after the bushings were in... put the tube back in...
The engine mount will be made by using a plywood jig.... So I made it now , to help
keep the front bushings in place...
Not only did it keep them in their place... it kept them lined up properly against the plywood...

I need 4 , but I made 8 for later use ( I should have made 12 )

  Anywho,
                 Here's some pictures.
                                                   Gotta Fly...
Attachments
Engine mount bushings.JPG
I made them a little long , Then trim them down afterwards.
Engine mount bushings.JPG (125.46 KiB) Viewed 10241 times
Engine mount bushings 01.JPG
Engine mount bushings 01.JPG (112.41 KiB) Viewed 10241 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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Rotaters

Postby planecrazzzy » Tue May 12, 2009 9:13 am

Hey guys... couple of notes on this subject...

   I found the center of weight at the front.... it was only a couple of inches off the line of engine mounts...

that I was bolting a rotating bar.... So I didn't offset the position...

at the tail... I was able to offset it , and compinsate for the weight a little....

What I failed to realize.... I was going to be putting in a bunch of 2 X 4's .... and that would be even more

weight off center.... It's not that bad... I'll deal with it.

  After I figured out what was needed.... I put "stops" on the pipes , so I could cut them short...

and not have to worry about them falling out of the stand.... gives me more room to walk around the Fuselage.

  Here's some Pictures...
                                          Gotta Fly...
Attachments
Rotating Fuselage 04.JPG
I was able to use some other stands I have, I just changed to top part for rotating... Saved a little work...
Rotating Fuselage 04.JPG (127.53 KiB) Viewed 10239 times
Rotating Fuselage 05.JPG
Rotating Fuselage 05.JPG (112.18 KiB) Viewed 10239 times
Rotating Fuselage 07.JPG
Rotating Fuselage 07.JPG (107.24 KiB) Viewed 10239 times
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Prepping for Weld

Postby planecrazzzy » Tue May 12, 2009 9:31 am

Hey Guys,
               I'm gonna put the cross brace 2 X 4's in each section...

I'm gonna cut them about 3/4" longer , to push out the tubing....

First... I go around the frame and make the tacks Bigger on the outside....to handle the strain.

Next , I cut the 2X4's .... Cut them one at a time for each bay.... The angle of the tubes are steep...

and one board will be further down the slope....

Speaking of steep slope... ( and slick tubes ).... These boards "DON'T" want to stay in place !!!

I tried several things... Here's what worked....  I took a piece of bailing wire... wrapped it twice around

the tube , and twisted it tight.... Now the board has something to Grip to.... Then after the board is pulled

and hit into place with yer rubber mallet.... Sneak another one on that side... Slide it as tight as you can , up to

the wood....   Then as your banging the other boards... it won't pop out....

    Here's some Pictures...

                                                  Gotta Fly...

PS  You can see in the pictures.... the tubes are pushed out just right... not too much...not too little. Ready to Weld
One more "Note" from Jim Clements "tricks"... The tubes should have a little bow out... Fabric will pull it in pretty good...
If there straight , the fabric will suck them in too much...
Attachments
HPIM0657.JPG
The Fuselage is Sideways
HPIM0657.JPG (121.04 KiB) Viewed 10237 times
HPIM0658.JPG
HPIM0658.JPG (124.69 KiB) Viewed 10237 times
HPIM0655.JPG
HPIM0655.JPG (126.49 KiB) Viewed 10237 times
Last edited by planecrazzzy on Fri May 15, 2009 5:11 am, edited 1 time in total.
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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