(07) Buttercup Leading Edge ( Mike )

Control Rods

Postby planecrazzzy » Tue Jan 13, 2009 7:19 pm

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...
Attachments
Leading edge to Flap - control rod 03.JPG
Leading edge to Flap - control rod 03.JPG (81.58 KiB) Viewed 4894 times
Leading edge to Flap - control rod 01.JPG
Leading edge to Flap - control rod 01.JPG (97.43 KiB) Viewed 4894 times
Leading edge to Flap - control rod.JPG
Leading edge to Flap - control rod.JPG (95.34 KiB) Viewed 4894 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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Control Rods

Postby planecrazzzy » Wed Jan 14, 2009 2:05 pm

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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Attachments
Leading edge to Flap control rod 05.JPG
Leading edge to Flap control rod 05.JPG (101.05 KiB) Viewed 4890 times
Leading edge to Flap control rod 06.JPG
Leading edge to Flap control rod 06.JPG (98.53 KiB) Viewed 4890 times
Leading edge to Flap control rod 08.JPG
Leading edge to Flap control rod 08.JPG (74 KiB) Viewed 4890 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 Prepped

Postby planecrazzzy » Tue Feb 10, 2009 8:08 pm

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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Attachments
Hinges Prepped 01.JPG
Hinges Prepped 01.JPG (94.43 KiB) Viewed 4870 times
Hinges Prepped 05.JPG
Hinges Prepped 05.JPG (101.85 KiB) Viewed 4870 times
Hinges Prepped 07.JPG
Hinges Prepped 07.JPG (111.24 KiB) Viewed 4870 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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Skinning the Leading Edge

Postby planecrazzzy » Thu Feb 12, 2009 7:30 am

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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Attachments
Leading Edge-2024T3 Skin 02.JPG
The lines on the ribs were VERY important... They can be seen thru the holes in the skin... and can be held at 90 degrees while drilling...
Then , when your on the other side and drilling in "The Blind" , you'll hit the ribs...I had no problems.
Leading Edge-2024T3 Skin 02.JPG (89.91 KiB) Viewed 4863 times
Leading Edge-2024T3 Skin 03.JPG
Leading Edge-2024T3 Skin 03.JPG (86.63 KiB) Viewed 4863 times
Leading Edge-2024T3 Skin 04.JPG
Leading Edge-2024T3 Skin 04.JPG (110.32 KiB) Viewed 4863 times
Last edited by planecrazzzy on Sun Feb 15, 2009 11:39 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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Leading Edge Skin

Postby planecrazzzy » Thu Feb 12, 2009 7:48 am

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
Attachments
Leading Edge-2024T3 Skin 05.JPG
Leading Edge-2024T3 Skin 05.JPG (90.15 KiB) Viewed 4862 times
Leading Edge-2024T3 Skin 06.JPG
Leading Edge-2024T3 Skin 06.JPG (87.06 KiB) Viewed 4862 times
Leading Edge-2024T3 Skin 07.JPG
Leading Edge-2024T3 Skin 07.JPG (98.84 KiB) Viewed 4862 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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Leading Edge Battle

Postby planecrazzzy » Thu Feb 12, 2009 6:39 pm

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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Attachments
Leading Edge-2024T3 Skin 10.JPG
This set-up is what finally worked to pull the skin over the ribs to start drilling.... Two horses with 3-- 2x4's
This bridges over the Hinges that are on the channel.... Then I used 4" vise grip Finger clamps, I used 4 plates to protect the thin ch
Leading Edge-2024T3 Skin 10.JPG (110.51 KiB) Viewed 4785 times
Leading Edge-2024T3 Skin 12.JPG
Leading Edge-2024T3 Skin 12.JPG (119.73 KiB) Viewed 4785 times
Leading Edge-2024T3 Skin 14.JPG
Leading Edge-2024T3 Skin 14.JPG (123.21 KiB) Viewed 4785 times
Last edited by planecrazzzy on Sun Feb 15, 2009 11:28 pm, edited 4 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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Leading Edge Skin

Postby planecrazzzy » Thu Feb 12, 2009 9:28 pm

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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Attachments
Leading Edge-2024T3 Skin 15.JPG
Leading Edge-2024T3 Skin 15.JPG (108.38 KiB) Viewed 4758 times
Leading Edge-2024T3 Skin 16.JPG
Leading Edge-2024T3 Skin 16.JPG (96.95 KiB) Viewed 4758 times
Leading Edge-2024T3 Skin 18.JPG
The "Lip" still needs to be "rolled", I'm waiting for rivets ... Then I'll do both leading edges...
Leading Edge-2024T3 Skin 18.JPG (104.87 KiB) Viewed 4758 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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2024 Skin

Postby planecrazzzy » Mon Feb 23, 2009 4:46 pm

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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Attachments
Leading Edge-2024T3 Skin-Drop for lower lip.JPG
Leading Edge-2024T3 Skin-Drop for lower lip.JPG (105.12 KiB) Viewed 4741 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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Leading Edge Lower Lip

Postby planecrazzzy » Fri Feb 27, 2009 8:15 pm

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
Attachments
Leading Edge Lower Lip 04.JPG
Leading Edge Lower Lip 04.JPG (104.43 KiB) Viewed 4732 times
Leading Edge Lower Lip 05.JPG
Leading Edge Lower Lip 05.JPG (104.65 KiB) Viewed 4732 times
Leading Edge Lower Lip 06.JPG
Leading Edge Lower Lip 06.JPG (107.98 KiB) Viewed 4732 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 Pics

Postby planecrazzzy » Fri Feb 27, 2009 8:17 pm

The rest of the lower lip pictures...
Attachments
Leading Edge Lower Lip 07.JPG
Leading Edge Lower Lip 07.JPG (103.05 KiB) Viewed 4731 times
Leading Edge Lower Lip 08.JPG
Leading Edge Lower Lip 08.JPG (107.4 KiB) Viewed 4731 times
Leading Edge Lower Lip 09.JPG
Leading Edge Lower Lip 09.JPG (121.91 KiB) Viewed 4731 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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Leading Edge Finished

Postby planecrazzzy » Sat Feb 28, 2009 5:32 pm

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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.
.
Attachments
Leading Edges Finished 01.JPG
Leading Edges Finished 01.JPG (120.46 KiB) Viewed 4723 times
Leading Edges Finished 02.JPG
Leading Edges Finished 02.JPG (116.01 KiB) Viewed 4723 times
Leading Edges Finished 03.JPG
Leading Edges Finished 03.JPG (116.6 KiB) Viewed 4723 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: Hinges

Postby taildragger_sp » Sun Sep 20, 2009 2:05 pm

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?  


planecrazzzy wrote: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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Postby planecrazzzy » Sun Sep 20, 2009 10:29 pm

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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Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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Postby taildragger_sp » Fri Dec 31, 2010 9:35 pm

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.
Attachments
leading edge hinge.jpg
leading edge hinge.jpg (139.52 KiB) Viewed 4636 times


Last bumped by planecrazzzy on Fri Dec 31, 2010 9:35 pm.
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