(05) Assembling Buttercup Wing -Ribs & Spars (Mike)

(05) Assembling Buttercup Wing -Ribs & Spars (Mike)

Postby planecrazzzy » Sat Jan 05, 2008 3:26 pm

OK,
     I'm done with the Ribs.....( except the "root rib" )

Since I've started working on shaping the spar's....seems like a good time to start a "Wing" topic....

For starters....I made my first cuts on my   1" X  5"  with my table saw....

But the wood had a bow , and the cut/trimming  ....Turned out less than satisfactory...

 So,  I used a combination square , and marked a line down the lenght of the spar....

With a plane , I shaved off most of the wood....

Then used a Block sander to finish....

  First one is done and it's a tight fit the whole lenght ( 11 ft )

(Finished the second 1" X 5" spar today also)

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

PS  Sharpened the "Plane Blade" today.... WOW....What'a difference
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Attachments
Spar - shaping 002.jpg
Spar - shaping 002.jpg (60.11 KiB) Viewed 7824 times
Spar - shaping 001.jpg
In the "final" finishing.... I had a RIB on the spar....and made sure it went down the whole Spar.
Spar - shaping 001.jpg (58.48 KiB) Viewed 7824 times
Last edited by planecrazzzy on Wed Sep 24, 2008 6:02 am, edited 3 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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Postby rganey » Sat Jan 05, 2008 11:16 pm

Looks good! I'm thinking of building a Buttercup and this visual info. helps a newbie like myself.


Randy
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Shaping Ribs

Postby planecrazzzy » Thu Jan 10, 2008 7:29 pm

Hey Guys,
               Well, I've got the spars that go through the ribs shaped....Before I shape the trailing edge piece,
I'll sandwich the ribs together on the spars , and do some light sanding to get the ribs exactly the same...
Their real close already....

Once I sand where the trailing edge goes , I'll have the measurement for shaping the angles of the trailing edge spar...

                    Gotta Fly...
                                    Mike & "Jaz" in MN  ( It's starting to look like a Wing )
Attachments
Wing 004.jpg
Wing 004.jpg (58.93 KiB) Viewed 7804 times
Wing 002.jpg
Wing 002.jpg (59.89 KiB) Viewed 7804 times
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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looks good

Postby rganey » Thu Jan 10, 2008 8:18 pm

That is some nice looking wood!   :D
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Re: looks good

Postby planecrazzzy » Sat Jan 12, 2008 8:33 am

Actually, I'm talking with Aircraft Spruce....I knew one spar was heavier than the other...
But I didn't realize just how much....The light one is 9 lbs ,  The heavy one is 14 lbs

Thats  5 lbs different....and I don't like it...

They might send me a new piece to match the "light one",  I'm still talking with them...

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

PS  They "ARE" sending me a new Spar , to match my Light one.... No Charge.......Thanks ACS
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rganey wrote:That is some nice looking wood!   :D
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Spar shaping

Postby planecrazzzy » Sun Jan 27, 2008 7:47 pm

I got my "NEW" spar from ACS....Got the rib to slide down the length....
Weighed my spars together ( each wing )

Had 2 lbs difference....Switched some pieces around to get both wings to weigh the same...

Then started shaping the "ends" of the spars ( Left & Right )

Here's some pictures....

                                                      Gotta Fly...
                                                                      Mike & "Jaz" in MN
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Attachments
Shaping Spar ends 004.jpg
Shaping Spar ends 004.jpg (58.04 KiB) Viewed 7781 times
Shaping Spar ends 003.jpg
Shaping Spar ends 003.jpg (60.14 KiB) Viewed 7781 times
Shaping Spar ends 002.jpg
Shaping Spar ends 002.jpg (58.72 KiB) Viewed 7781 times
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Spars are shaped

Postby planecrazzzy » Sun Feb 03, 2008 3:42 pm

Today I "layed out" the spars....Trim cut them , and marked the Rib spacing....

I've got the Ribs on the Spars , I'll be ready to Drill/ screw the aileron spar on next....

I'm thinking about Stainless steel screws...

I like these "horses" .....I can adjust the leg height....

Before I do anything , I need to bring my digital protractor home and check

that the horses are level to each other....So I don't build "in" a wash.

          Had a picture with "Jaz" in it....But it came out Blurry...

                               Gotta Fly...
                                               Mike & "Jaz" in MN
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Attachments
Wing 011.jpg
Wing 011.jpg (58.72 KiB) Viewed 7773 times
Wing 008.jpg
Wing 008.jpg (59.97 KiB) Viewed 7773 times
Wing 007.jpg
Wing 007.jpg (60.75 KiB) Viewed 7773 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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More Wings

Postby planecrazzzy » Mon Feb 04, 2008 8:17 pm

Not bad for not having any "room".... I've got both wings ready to work on...

                Gotta Fly...
                                Mike & "Jaz" in MN
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Attachments
Wing 015.jpg
Wing 015.jpg (59.66 KiB) Viewed 7763 times
Wing 013.jpg
Wing 013.jpg (60.06 KiB) Viewed 7763 times
Wing 012.jpg
Wing 012.jpg (59.65 KiB) Viewed 7763 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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a little glue

Postby planecrazzzy » Sun Feb 10, 2008 9:55 am

Hey Guys,
               I have the screws to attach the "aileron spar"....
But everything moves too much.....
     
       So, I stood the wing up on it's Front Spar , and glued the ribs ( w/full plywood ) to the front spar...

This morning, I went out , Turned the wings over....and glued the same ribs to the rear spar.....

 Now, the wing will hold "square" alittle better while I attach the aileron spar , and glue the rest of the ribs....

                                        Gotta Fly...
                                                        Mike & "Jaz" in MN
Attachments
Wing 018.jpg
Wing 018.jpg (59.28 KiB) Viewed 7753 times
Wing 016.jpg
Wing 016.jpg (60.12 KiB) Viewed 7753 times
Wing 017.jpg
Wing 017.jpg (61.6 KiB) Viewed 7753 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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Next step

Postby planecrazzzy » Sun Feb 17, 2008 8:52 pm

Hey Guys,
              The next step is to put the Spar "Fillers" in....

They go between the ribs....There's some questions that I've asked Earl about
Where to put them....Prints and his construction photos don't match up...

 It looks like they go on the Front Spar only ( Top & Bottom )

 Here's some recent photos....

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

PS   Earl Replied,  Yes , Front Spar only - Top & Bottom
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Attachments
Wing spar filler 005.jpg
This doesn't "JIVE" with the building photos
Wing spar filler 005.jpg (59.91 KiB) Viewed 7741 times
Wing spar filler 04.jpg
I used rubberbands held with a nail
to hold the filler piece to the spar while the epoxy drys...
Wing spar filler 04.jpg (58.99 KiB) Viewed 7741 times
Wing spar filler 03.jpg
Wing spar filler 03.jpg (56.9 KiB) Viewed 7741 times
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Sanding Spar Fillers

Postby planecrazzzy » Sun Mar 02, 2008 2:07 pm

Hey Guys,
              I've got the garage closed because there's snow outside....I was block sanding the
spar filler material , power sanding just makes a mess in the garage

But that was too much work , and taking too long.... So I went at it with one of my small
air grinder/sander....wasn't too bad ....There was still alot of block sanding to do...

Later I'll just get some Fans going , and use the compressor to blow the garage out....

Now that the "fillers" are in....next is the Birch ply....followed with the triangle blocks....

                                            Gotta Fly...
                                                            Mike & "Jaz" in MN
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Attachments
Wing spar filler 015.jpg
Wing spar filler 015.jpg (60.85 KiB) Viewed 7724 times
Wing spar filler 012.jpg
Wing spar filler 012.jpg (56.34 KiB) Viewed 7724 times
Wing spar filler 011.jpg
Wing spar filler 011.jpg (57.62 KiB) Viewed 7724 times
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Birch Plywood

Postby planecrazzzy » Sat Mar 15, 2008 1:43 pm

Putting some of the Birch Plywood on the Front Spar...

The ones for the Lift Strut are 3/16 inch thick....

The ones for the leading edge pivot hinges are  1/16 inch thick

                          Gotta Fly...
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Attachments
Band Saw 008.jpg
Bought a bandsaw to help with some of the cutting...Made a quick "stand" for it at work...
Band Saw 008.jpg (58.54 KiB) Viewed 7712 times
Birch plywood 002.jpg
1/16 Birch Plywood
Birch plywood 002.jpg (58.6 KiB) Viewed 7712 times
Birch plywood 001.jpg
3/16 Birch Plywood
Birch plywood 001.jpg (58.24 KiB) Viewed 7712 times
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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A couple more Spar Caps

Postby planecrazzzy » Sat Mar 22, 2008 8:41 pm

I put the spar caps on the "root end" today....

First , I soaked the pieces after I sanded them with a "taper"....

Then I poured a tea pot of steaming hot water on them....

Brought them out to the garage and used rubberbands to hold them in place ( twisted )

 I let them dry....

Then I took the rubberbands off.....added some epoxy , and put the rubberbands back on till

the epoxy drys.....

Tomorrow I'll put the birch plywood on the Root ends...

                                    Gotta Fly...
                                                    Mike & "Jaz" in MN
Attachments
Wing spar filler 022.jpg
Wing spar filler 022.jpg (58.52 KiB) Viewed 7694 times
Wing spar filler 018.jpg
Wing spar filler 018.jpg (59.82 KiB) Viewed 7694 times
Wing spar filler 017.jpg
Wing spar filler 017.jpg (58.09 KiB) Viewed 7694 times
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Postby Allen » Sat Apr 05, 2008 12:42 am

Mike,

I'm enjoying watching the outcome of your work.  It's excellent.  When shaping the spar ends, particularly the ones with the compound angles, did you use a saw and if so what did you use and how?

Allen in Anchorage :mrgreen:
Give me Liberty, or give me death.
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Sawing Spars

Postby planecrazzzy » Sat Apr 05, 2008 5:25 pm

Hi Allen,
             At the Very beginning.... I tried to use a table saw for cutting....

I dropped that idea quick.....  "I"  wasn't getting good results....

 So from that point on , I've been "Planeing" and using a "Hand Saw "  (Fine tooth)

 I was able to use a couple different band saw for cutting the plywood and the small spruce.

                                  Gotta Fly...
                                                  Mike & "Jaz" in MN
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Allen wrote:Mike,

I'm enjoying watching the outcome of your work.  It's excellent.  When shaping the spar ends, particularly the ones with the compound angles, did you use a saw and if so what did you use and how?

Allen in Anchorage :mrgreen:
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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