(06) Metal Tubing & Hardware for BC Wings ( Mike )

Wing Tip / Trailing Edge

Postby planecrazzzy » Thu Jun 26, 2008 7:16 pm

Here's some pictures of my Trailing edge....The prints are a little Vauge in this area...

It's not attached yet... But it's got a good fit.

I need to weld a bracket on the Trailing Edge to bolt it to the Wood ...

Gotta Fly...
Attachments
Wing Tips 011.jpg
Wing Tips 011.jpg (59.95 KiB) Viewed 4064 times
Wing Tips 012.jpg
Wing Tips 012.jpg (60.03 KiB) Viewed 4064 times
Wing Tips 013.jpg
Wing Tips 013.jpg (59.96 KiB) Viewed 4064 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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Trailing Edge

Postby planecrazzzy » Sat Jun 28, 2008 2:38 pm

OK,
      Here's some close up pictures of how "I" did the trailing edge...

Mostly showing how I shaped the wood that the trailing edge bolts onto....

                             Gotta Fly...
                                               Mike & "Jaz" in MN
.
.
.
Attachments
Wing Tips 014.jpg
Wing Tips 014.jpg (57.5 KiB) Viewed 4058 times
Wing Tips 015.jpg
Wing Tips 015.jpg (58.06 KiB) Viewed 4058 times
Wing Tips 016.jpg
Wing Tips 016.jpg (57.49 KiB) Viewed 4058 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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Wing Tip Ribs

Postby planecrazzzy » Sat Jun 28, 2008 6:26 pm

I've got the Piper channel Ribs formed and tacked into the Wing Tip...

I still need to put a few reinforcing pieces on them....

                                      Gotta Fly...
                                                      Mike & "Jaz" in MN
.
.
.
Attachments
Wing Tips 020.jpg
Wing Tips 020.jpg (60.25 KiB) Viewed 4056 times
Wing Tips 023.jpg
Wing Tips 023.jpg (59.93 KiB) Viewed 4056 times
Wing Tips 024.jpg
Wing Tips 024.jpg (60.61 KiB) Viewed 4056 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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Bracing ribs

Postby planecrazzzy » Sun Jun 29, 2008 11:36 am

Last , but not least...Reinforcing braces on the Wing Tip Ribs....

It's not the way Earl's got it in his building photos....

But it's simple and strong...

I used scrap pieces of the Piper Channel...

                                           Gotta Fly...
                                                           Mike & "Jaz" in MN
.
.
.
Attachments
Wing Tips 026.jpg
Wing Tips 026.jpg (59.02 KiB) Viewed 4050 times
Wing Tips 025.jpg
Wing Tips 025.jpg (59.59 KiB) Viewed 4050 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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Right Wing Tip

Postby planecrazzzy » Sat Jul 05, 2008 4:19 pm

Hey Guys,
               I just finished tacking up the Right Wing Tip.... Turned out pretty good....
I used the left side to help roll the Piper channel to the same curves....
Here's some pictures...

                                            Gotta Fly...
                                                            Mike & "Jaz" in MN
.
.
.
Attachments
Wing Tips - Right Wing 001.jpg
Wing Tips - Right Wing 001.jpg (60.68 KiB) Viewed 4037 times
Wing Tips - Right Wing 002.jpg
Wing Tips - Right Wing 002.jpg (61.48 KiB) Viewed 4037 times
Wing Tips - Right Wing 003.jpg
Wing Tips - Right Wing 003.jpg (59.45 KiB) Viewed 4037 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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Wing - Compression Strut

Postby planecrazzzy » Sat Jul 12, 2008 11:28 am

Here's the best I could "Guess" where to put the Compression Strut....

It's so close , the nuts won't need to be held with another wrench when tightened....

It looks pretty level....and fairly "square"....

I still need the holes in it to hold the 3/4 flat bar , that the cable attaches to.....
.
.
                                  Gotta Fly...
                                                                          Mike & "Jaz" in MN
.
.
.
Attachments
Wing - Compression strut 003.jpg
Wing - Compression strut 003.jpg (56.57 KiB) Viewed 4028 times
Wing - Compression strut 002.jpg
Wing - Compression strut 002.jpg (61.44 KiB) Viewed 4029 times
Wing - Compression strut 004.jpg
Wing - Compression strut 004.jpg (56.85 KiB) Viewed 4029 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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Spar Connectors

Postby planecrazzzy » Tue Jul 15, 2008 3:59 pm

Hey Guys,

Looks like another "Grey" area....

I'll write down "MY" measurement.... If anything is "off" too much , I'll come back here and
change the message.... ( it should be real close )

Front Spar - I measured 1-1/4" from the "bottom" of the Spar to the center of the holes...

Rear Spar -  I measured 1-1/4" from the "TOP" of the Spar to the center of the holes...

This looks about right , and looks like the Cross Cables will clear the ribs....

( Measurement for the holes in the Compression strut later , their already "marked"  )

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



These measurements worked out GREAT... I moved the Cabin Rear cross tube "UP" one inch , as high as it would go
This is better for headroom clearance...


Attachments
Wing - Spar connectors 002.jpg
Wing - Spar connectors 002.jpg (59.66 KiB) Viewed 4018 times
Last edited by planecrazzzy on Thu Oct 15, 2009 10:26 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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Wing - Compression Strut

Postby planecrazzzy » Sun Aug 10, 2008 6:02 pm

Hey Guys....

                  Camera problems , But I've got a spare... OK , What we're looking at will be
the "Tangs" for the cross braces... All the small ones were cut at 2".....12 of them

The longer ones were cut at 4".....4 of them

Most holes were 1/4"......... a few were 3/16" ....watch the bolts

All bends were at 3/4" from the end of the tang

                                      Gotta Fly...
                                                      Mike & "Jaz" in MN
Attachments
HPIM0199.JPG
HPIM0199.JPG (106.46 KiB) Viewed 4008 times
HPIM0206.JPG
HPIM0206.JPG (108.26 KiB) Viewed 4008 times
HPIM0204.JPG
HPIM0204.JPG (100.95 KiB) Viewed 4008 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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Wing - Compression Strut

Postby planecrazzzy » Sun Aug 10, 2008 6:16 pm

Hey Guys,
                I have a measurement fot the Bolts on the compression strut , that holds the "tangs"

Front Spar -  From the PLYWOOD , measure  2  3/8"...... 1/4" hole thru the tube

Rear Spar -  From the PLYWOOD , measure  1  1/4".......1/4"  hole thru the tube




                                               Gotta Fly...
                                                               Mike & "Jaz" in MN
Attachments
HPIM0202.JPG
Rear spar...hole is 1 1/4" from plywood....1/4" hole thru Tube
HPIM0202.JPG (104.76 KiB) Viewed 4007 times
HPIM0205.JPG
Front Spar ...Hole is 2 3/8" from plywood....1/4" hole thru Tube
HPIM0205.JPG (101.02 KiB) Viewed 4007 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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4" tangs

Postby planecrazzzy » Sun Aug 10, 2008 6:24 pm

Hey Guys...


The 4" tangs at the Wing tips , are centered....but the space from the Rib varys...See pictures

       Gotta Fly...
                       Mike & "Jaz" in MN
.
.
.
Attachments
HPIM0206.JPG
The front spar....The hole is centered ( up & down ) the measures 1 3/8" from the rib...
HPIM0206.JPG (108.26 KiB) Viewed 4005 times
HPIM0203.JPG
The rear spar....the hole is centered ( up & down) then measures 7/8" from the rib...
HPIM0203.JPG (99.89 KiB) Viewed 4005 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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Hinges

Postby planecrazzzy » Fri Aug 22, 2008 1:46 pm

Hey Guys,
               Started on the Flaps & Ailerons.... First step ,  Hinges...

 I need to weld them up before sliding them down the aileron & Flap tubes....

They're already close tolerance, after welding they'll need to be cleaned up with

a Flapper wheel so they clear the tube.... a flapper wheel will leave a smoother

surface than a die grinder....

 I made a simple "jig" to put them together....

                                          Gotta Fly...
                                                          Mike & "Jaz" in MN
Attachments
Hinges.JPG
Hinges.JPG (118.94 KiB) Viewed 3992 times
Hinges 03.JPG
Hinges 03.JPG (113.72 KiB) Viewed 3992 times
Hinges 07.JPG
Hinges 07.JPG (108.95 KiB) Viewed 3992 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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Hinges Cleaned up

Postby planecrazzzy » Sat Aug 23, 2008 5:32 pm

Hey Guys,
               I cleaned up the Hinges after welding....

  I used the Die grinder to take the humps out behind the weld.... Then I circled around a bit to remove some bulk...

Then I used the drum sander to remove more bulk , but keep things even.....

Last , I used the Flapper wheel to get a nice smooth finish   ( 40 grit )
.
.

The .058 tubing was already tight before I welded.... it took a few different stages of grinding
to get the hinges to slide over the Aileron/ Flap tube with clearance....

( tubing should have been .035 , But the ACS cut list said .058 )

                                      Gotta Fly...
                                                      Mike & "Jaz" in MN
.
.
.
Attachments
Hinges cleaned up 02.JPG
Hinges cleaned up 02.JPG (125.19 KiB) Viewed 3984 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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Aileron tubing

Postby planecrazzzy » Wed Aug 27, 2008 9:31 pm

Hey guys,
              I'm working on the tube for the Aileron.... Prints call for the tube to be flattened at one end...
( not totaly flattened )

Anyway , I tried to give the material a place to go.... otherwise the tube would squish out both sides....

Can't have the tube doing that on the side that is close to the wood.... So , I cut a line 3 1/2" into the tube...

I left a little on the end , just to help keep things lined up....

It didn't do any good..... BUT.... I then cut more of the line....made it a "V"  ( SLIGHT )...

The tapped it around and welded it back together..... Now the tube is straight on the "Hinge Side" after it has been

flattened ( Down to 1/2" to meet the end tube )

   Anywho,
                 Here's some Pics...

                                                  Gotta Fly...
                                                                  Mike & "Jaz" in MN
.
.
.
Attachments
Aileron tubing.JPG
Aileron tubing.JPG (95.54 KiB) Viewed 3977 times
Aileron tubing 01.JPG
Aileron tubing 01.JPG (99.78 KiB) Viewed 3977 times
Aileron tubing 02.JPG
Aileron tubing 02.JPG (97.21 KiB) Viewed 3977 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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Aileron tube

Postby planecrazzzy » Wed Aug 27, 2008 9:34 pm

More Pictures of the Aileron tube
Attachments
Aileron tubing 04.JPG
Aileron tubing 04.JPG (82.16 KiB) Viewed 3976 times
Aileron tubing 03.JPG
You can "SORTA" see how much flattening the tube made it stick out pretty far....One side doesn't matter
Aileron tubing 03.JPG (74.84 KiB) Viewed 3976 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

Aileron/ Flap cord length

Postby planecrazzzy » Sat Aug 30, 2008 11:53 am

Hey Guys,
               Another "Grey" area.... I cut my tubing ( 3/8 X .035 ) for the cord length of my Flaps & Ailerons...

 I cut them at 6  3/4".... Total cord length should be 8"  ( My best guess )


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

PS.... It looked like the cord should have been a little shorter.... I stretched it out a little further....
Attachments
Aileron- Flap Tubing-12 each wing.JPG
Aileron- Flap Tubing-12 each wing.JPG (109.07 KiB) Viewed 3969 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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