(07) Buttercup Leading Edge ( Mike )

[planecrazzzy]

Hey Guys,
               Finally got the other tubes... Wow, two 1/2" X .035  X 42" tubes, after shipping  $28 bucks....

Anywho,
              Made my clevis's for the Flap horn control...  Cheaper , lighter....

                             Gotta Fly...

[planecrazzzy]

Hey Guys,
               I got the holes in the spar big enough.... I fit things up several times to get the hole as small as needed...

Also... I made comments earlier that the control arm (stock) needed the hole an inch passed where the prints showed...

Ends up it only needed to be 1/2 inch passed the stock control horn.... But I'm going to leave the other hole in the control horn

to experiment with.... I usually don't use full flaps.... maybe having extra "throw" in the leading edge could be good...(?)

As it is right now...The leading edge is moved forward/down  1-1/2" ... That's "stock"....

The stock hole for the control horn wouldn't work without bending the control rod.... it hits on the rear spar

                                                   Gotta Fly...
                                                                   Mike & "Jaz" in MN
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[planecrazzzy]

Hey Guys,
               I've got the Leading Edge "Hinges" welded , Cleaned, straightened, Primered with Zinc Chromate and

epoxied on the leading edge ..... I added 4 rivets to help hold it during the skinning process....

Before I put the Epoxy on , I scuffed up the Aluminum where the Hinges mount....

The Prints call for JB weld..... I used my West System Epoxy...

Right now , it's also being held with Cleco's til tomorrow....the epoxy should be dry then....

 I'll clean an area and move tables to put the Skins on the leading edges.... Oh boy....

                           Gotta Fly...
                                           Mike & "Jaz" in MN
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[planecrazzzy]

Hey Guys,
               I'm skinning the Leading edge with 2024T3  ,  I bought them at Aircraft Spruce...

18X144X.016  for $48 bucks each.....I bought two.

 Below are some pictures of my "lay-out" on the leading edge....

I put lines down the Rib "stubs" , So I could reach around and hold it straight during drilling....( They Helped )

I extended those lines to the Channel.... and used them to mark the leading edge "Skin"...

I put lines on the sheet.... and drilled the rivet holes for one side....

I used the edge of the channel to help line up the sheet "square"

                                        Gotta Fly...
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[planecrazzzy]

Hey Guys,
                OK,  At this point I have the Skin Cleco'ed on one side... I've pulled the Skin over....

Trying to pre bend the skin.... It's not working very good....

I thought if I got it close.... I'd take the skin off , and bend it over more.

But since it's not working , I'm afraid it'll bend (kink)at the rivet line...

So, my plan will be to Rivet what I've got to this point....

Then make some "Cradles" to help push the skin in shape....

If I had someone to help , I wouldn't need it....

With the Overhanging "lip" , It's too awkward for one person.

With the cradles , I might be able to put better pressure on the leading edge to hold the skin tight for Drilling.

I'll be drilling in the "Blind"... But I have my Lay-out lines on the sheet....

The Ribs are pretty straight (square) , so my lines should help

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

[planecrazzzy]

Hey Guys,
               Messing with this Awkward , Flimsy , Springy Skin.... Has been a Battle...

I finally found a way to Hold the frame , While pulling the skin over the nose of the Ribs...

During some of my screwing around... I managed to kink the skin a little....

The next one should come out fine... I noticed Earl had a little "Bondo" in his...

Guess I'll be doing the same...

 I had Cleco's on one side... But I found that I needed to take a few off ...

That way I could clamp it from the opposite side I was working on....

 I clamped a  1/4 X 2 X 144 piece of steel to the "Lip".... and I hung four - 9 lb weights on it....

  It worked....

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

Note... After I got rivets and clecos around the area that krinkled on me..... I tapped them a little with a hammer....
and they came out.... They're is a slight hint.... But I think it'll be fine.... I was suprised and GLAD !
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[planecrazzzy]

Hey Guys,
               Getting things buttoned up tighter...

Notice the "RED" rivets on the Bottom.... Those are Aluminum rivets that will be drilled out later to add the
extension that goes on the lower part of the leading edge...I used them So I can drill all the holes along that edge
I'll put one more aluminum rivet between each of those to hold it a little better... They drill out easy...

                          Gotta Fly...
                                          Mike & "Jaz" in MN
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[planecrazzzy]

Hey Guys,
                I bought the 2024T3 sheets from ACS ... They were 18" X 12' ....

From this .... 32.5" was trimmed off....

I just sheered four pieces out of each Drop at 3.75" wide....

This will work for my lower lip on the leading edge....

I was going to butt them by two's and weld them.... But after looking at how the lower lip

is so "BUSY".... I'm going to make it in four sections... ( No welding needed )

They'll stop at both hinges and at the lift strut supports.

Before I do this , I'm going to set my cables... That way I'll get tight lines on the lower lip splices....

                   Gotta Fly...
                                   Mike & "Jaz" in MN
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[planecrazzzy]

Hey guys,
               I've got one of the leading edge "lower lip" set in place.... As I said, I used the drops from
the leading edge Skin...  The sheets "meet" at the Hinges and the Lift strut arms... See pictures.

   I like the way it turned out... and it was cheap.... I could weld the splices , but there's no need to do it.

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

[planecrazzzy]

The rest of the lower lip pictures...

[planecrazzzy]

Hey guys,
              I've got both leading edges finished.... The Top & Bottom "Lips" are curved to fit the airfoil...

But they'll need to be tweeked at final assembly....Only thing left is to Paint them..... I'll wait

                          Gotta Fly...
                                          Mike & "Jaz" in MN
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[taildragger_sp]

I think I know why...there is a line on the plans where you welded on the tab.  I think there was supposed to be a slot cut in the steel to allow the tab to fit inside.  This would move the tab back so it would not need to be cut off.  I wonder if we are supposed to cut the slot through bth sides and weld the back, front and bottom for strength?  Thanks for all the pictures.  Also, on the plans the second mounting 'hole' is outside the bracket.  It looks better your way but I wonder if oxy/gas welded it might be a problem with strength?  

Hey Guys,
               I've got the Wing hinge ready to mount before I drill the Pivot Hole...

The tabs that the hole gets drilled into were made to the dimensions... But there just too long.

  Once I figure where the hole goes , I'll trim them down...

                                                   Gotta Fly...
                                                                   Mike & "Jaz" in MN
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[planecrazzzy]

I'll go back and look at that.... you might be right...That would be the case with Both Hinge arms....?

    Just really doesn't seem like it would make it stronger.... I'll also check earls building pictures...

                            Gotta Fly...
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[taildragger_sp]

I am trying to attach 1 of Earl's construction photos.  I hope it works.  It shows the weld along the bottom and the front.  I was just going over the plans and tried to answer your posted question about why the extra length.  I think your hinges came out looking great, very polished.  
I was concerned about the difference between TIG that you are using and someone like me following you but using oxy/gas.  May not be a valid concern (with the hole in the tube but being welded back up and all.)  It was different than the plans and I was just curious.