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

Hinges

Postby planecrazzzy » Sun Aug 31, 2008 2:02 pm

OK,
     I've got the Hinges mounted.... I put a shim in back of each Hinge before I drilled them....

That should be enough room for two of the fabric thickness...

I used a THICK paper , and folded it.... ( see picture )

          The control tubes turn easy....

                                                      Gotta Fly...
                                                                      Mike & "Jaz" in MN
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Attachments
Hinges for Ailerons and Flaps.JPG
Hinges for Ailerons and Flaps.JPG (124.89 KiB) Viewed 4537 times
Hinge- Spaced out ,for Fabric.JPG
Hinge- Spaced out ,for Fabric.JPG (92.9 KiB) Viewed 4537 times
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Aileron-Flap Tubing

Postby planecrazzzy » Mon Sep 01, 2008 5:12 pm

Hey Guys,
               I've got the tubing "tacked" ....Still more to do to it , I'll flatten the ends later.
This way I know they'll be flattened in line , I'll probably use the floor and a block of steel...

 I'm doing the Ailerons a little different than the prints....

                                Gotta Fly...

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Mistake Correction "NOTE"

When I ordered the Flap Tubes , It was cheaper to have them shipped at 8 ft lengths , I found out they were SHORT by 1 inch...

I'll have to weld a splice now...

Maybe 8 ft 2 inch would be a good start , then trim it down from there.
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Attachments
Aileron-Flap Tubing.JPG
Aileron-Flap Tubing.JPG (114.77 KiB) Viewed 4533 times
Aileron-Flap Tubing 02.JPG
Aileron-Flap Tubing 02.JPG (128.06 KiB) Viewed 4533 times
Aileron-Flap Tubing 03.JPG
Aileron-Flap Tubing 03.JPG (131.09 KiB) Viewed 4533 times
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Aileron Torque Tube

Postby planecrazzzy » Sat Sep 06, 2008 8:34 pm

Hey Guys,
               I got the Tube from ACS the other day  ( 1 1/8" )  for the Spacer between the Aileron tube , and the

Torque tube...  The prints say to weld and heat an 1/8" rod to use for a spacer between the tubes....

I used an 1/8" rod , But I made my spacers different....  The Torque tube is 3/4".... I wrapped the rod around

a 5/8" tube several times, then cut the rings....opened them a little and hammered them onto the 3/4"tube,

Then slipped on the Spacer tube and welded it .   ( see pictures )


Also , it calls for Building up the spacer "more" with brass ( or whatever )  I don't think there's enough slop to worry about.

                               Gotta Fly...
                                               Mike & "Jaz" in MN
Attachments
Aileron spacers 01.JPG
Aileron spacers 01.JPG (73.83 KiB) Viewed 4519 times
Aileron spacers 06.JPG
Aileron spacers 06.JPG (102.01 KiB) Viewed 4519 times
Aileron spacers 04.JPG
Aileron spacers 04.JPG (98.05 KiB) Viewed 4522 times
Last edited by planecrazzzy on Sun Sep 07, 2008 11:20 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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More pictures

Postby planecrazzzy » Sat Sep 06, 2008 8:37 pm

Here's some more pictures...
Attachments
Aileron spacers 07.JPG
Aileron spacers 07.JPG (115.79 KiB) Viewed 4509 times
Aileron with torque tube  01.JPG
Aileron with torque tube 01.JPG (100.36 KiB) Viewed 4509 times
Aileron and Flap tube fit up - plug weld example.JPG
Aileron and Flap tube fit up - plug weld example.JPG (41.5 KiB) Viewed 4509 times
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Update

Postby planecrazzzy » Sat Sep 13, 2008 6:58 pm


Hey Guys,
               Today I took off the Flap & Aileron tubes and straightened them... a little heat , a little pressure...

 Then I fit the trailing edge to them after smashing the tubes and grinding the trailing edge to fit the tubes...

A very nice fit....  Tacked it together.

Something I never liked was the funny angle the Aileron had with the Wing Tip....

I changed the angle of the Trailing edge on the wing tip when I built them....

Then when I built the Aileron I matched it.... It's a little of "Taking from Peter & giving to Paul"

I like the "Flow" .... Nice lines coming off the wing tip to the Aileron....

Now I just have to "Match" the other side....

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

Oh, another thing I changed... I used Trailing edge at the end of the Aileron , instead of 1/2 tube.
       
Attachments
Trailing Edge 05.JPG
Trailing Edge 05.JPG (101.49 KiB) Viewed 4502 times
Trailing Edge 08.JPG
Trailing Edge 08.JPG (120.69 KiB) Viewed 4502 times
Trailing Edge 09.JPG
Trailing Edge 09.JPG (123.54 KiB) Viewed 4502 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 / Aileron Mod

Postby planecrazzzy » Sun Sep 14, 2008 1:37 pm

Hey Guys,
               I have some details how I modified the Wing tip / aileron angles...

 In the picture , you can see the square lines up with the Hinge and the aileron...

In the print picture , you can see the way I changed the trailing edge of the wing tip

by leaving the trailing edge spar out from the rib by 5"  instead of 3  7/8"

   I also made the aileron longer by robbing as much of the flap area as I could....

I couldn't take more because of the leading edge control rod.

I wasn't sure that I would get a clean straight line.... ( But I did )

I at least wanted to take most of the angle out of it...

   Here's some pictures.
                                          Gotta Fly...
                                                          Mike & "Jaz" in MN

 
I measured the Sq inch on a Stock aileron.... and also on my Custom Aileron...

Mine has 10.5" MORE Sq inches ...( cool )
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Attachments
Trailing Edge 11.JPG
Trailing Edge 11.JPG (107.34 KiB) Viewed 4496 times
Trailing Edge 12.JPG
Trailing Edge 12.JPG (108.15 KiB) Viewed 4496 times
Trailing Edge 16.JPG
Trailing Edge 16.JPG (134.97 KiB) Viewed 4496 times
Last edited by planecrazzzy on Wed Feb 04, 2009 6:17 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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Flaps & Ailerons Tacked

Postby planecrazzzy » Tue Sep 16, 2008 6:46 pm

Hey Guys,
               I was out in the Garage finishing putting the Piper channel on the Flaps & Ailerons...

I stepped back after....and realized , I'm done with them for a while....

Looks like I'll be starting the leading edge next....

 Here's a few pictures of the Piper channel "capping off" the Flaps & Ailerons.

                                         Gotta Fly...
                                                         Mike & "Jaz" in MN
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Attachments
Trailing Edge 20.JPG
Trailing Edge 20.JPG (107.25 KiB) Viewed 4482 times
Trailing Edge 18.JPG
Trailing Edge 18.JPG (104.4 KiB) Viewed 4482 times
Trailing Edge 23.JPG
Trailing Edge 23.JPG (114.45 KiB) Viewed 4482 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 Welded

Postby planecrazzzy » Fri Jan 30, 2009 6:07 am

Hey Guys,
               I welded up one of the Wing Tips today...

    I welded the Structual areas with Hard Wire  ( MIG )... and the rest with Silicone Bronze.... ( TIG )

I have it mounted back on the wing... There was minimum Warping  Turned out nice....

 When I cleaned up the welds with a grinder & sander .... I left a little extra material ( Silicone Bronze )

  Here's some pictures...
                                    Gotta Fly...
                                                    Mike & "Jaz" in MN
Attachments
Welded Wing Tip 01.JPG
Welded Wing Tip 01.JPG (89.32 KiB) Viewed 4408 times
Welded Wing Tip 04.JPG
Welded Wing Tip 04.JPG (96.19 KiB) Viewed 4408 times
Welded Wing Tip 05.JPG
Welded Wing Tip 05.JPG (84.29 KiB) Viewed 4408 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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Hinge- Fabric Tabs

Postby planecrazzzy » Wed Feb 04, 2009 6:12 pm

Hey Guys,
                There's nothing supporting the area around the Flap and aileron Hinges...

So I got some "Banding Material" and made some pieces to bridge the gap... They're light...

and the banding material is some tough stuff...( ruined a brand new Band saw blade )

I will probably need them on the Elevator and Rudder later.....

                                        Gotta Fly...
                                                        Mike & "Jaz" in MN
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Attachments
Hinge-Fabric Tabs 01.JPG
Hinge-Fabric Tabs 01.JPG (112.03 KiB) Viewed 4395 times
Hinge-Fabric Tabs 03.JPG
Hinge-Fabric Tabs 03.JPG (89.15 KiB) Viewed 4395 times
Hinge-Fabric Tabs 04.JPG
Hinge-Fabric Tabs 04.JPG (83.44 KiB) Viewed 4395 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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Cross Cables in Wings

Postby planecrazzzy » Tue Feb 24, 2009 6:37 pm

Hey Guys,
               I've been working on the Leading edge... and got to the point where I needed the wing to
be held secure , in order to get a good fit on the lower lip of the leading edge... So I put in the Cables
and Turnbuckles....
   Not much explaining to do.... But I thought I'd throw in some pictures anyway...

Once the final assy is done , The Turnbuckles will have to be Safety Wired... Good examples in ACS catolog

I did manage to catch Jaz in one of the pictures...

                                             Gotta Fly...
                                                             Mike & "Jaz" in MN
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Attachments
Nicco Swagging.jpg
Nicco Swagging.jpg (45.07 KiB) Viewed 4375 times
Cables 01.JPG
Cables 01.JPG (76.89 KiB) Viewed 4375 times
Cables 08 Swaggs Finished.JPG
Cables 08 Swaggs Finished.JPG (78.21 KiB) Viewed 4375 times
Last edited by planecrazzzy on Thu Feb 26, 2009 2:42 pm, 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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More Pics

Postby planecrazzzy » Tue Feb 24, 2009 6:39 pm

More Pictures
Attachments
Cables 04.JPG
Cables 04.JPG (89.51 KiB) Viewed 4379 times
Cables 05.JPG
Cables 05.JPG (83.3 KiB) Viewed 4379 times
Cables 06.JPG
Cables 06.JPG (112.88 KiB) Viewed 4379 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

Blasting parts

Postby planecrazzzy » Thu Apr 02, 2009 7:58 pm

Hey Guys,
               I'm blasting my Wing parts now...
I've bought the AN bolts and hardware... So after epoxy primer and Color Coat ,
I'll assemble alot of things onto the wing to stay....

My "set up" for Sand Blasting my parts is a portable 5hp Compressor connected along with my
shop elec compressor to give me a good flow of air.... I'm using Silica sand.
I made a little something to catch the sand.... to use it again ( and again )
I have a trailer frame that worked good for this.....
As I'm spraying , I lose "some" sand.... but not much.

                                  Gotta Fly...
                                                  Mike & "Jaz" in MN
Attachments
Sand Blasting wing parts 01.JPG
Sand Blasting wing parts 01.JPG (130.35 KiB) Viewed 4336 times
Epoxy Primer and color coat 01.JPG
This really "is" some good Epoxy Paint...
http://klasskote.com/index.html
Epoxy Primer and color coat 01.JPG (134.29 KiB) Viewed 4336 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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Re: Metal Tubing & Hardware for BC Wings ( Mike )

Postby planecrazzzy » Sat Jul 17, 2010 6:22 am

Here's a couple pictures after I assembled things to check "Fit"
.
Gotta Fly...
Attachments
Buttercup Outside 009.jpg
Buttercup Outside 010.jpg
Buttercup Outside 011.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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