(12) Controls ( Mike )

Travel

Postby planecrazzzy » Thu Oct 29, 2009 5:31 am

Hey Guys,
                I've got the bellcranks mounted...as of now they are spaced out from the weld with a "tube sleeve"
it's a 1/4" long , it's a better surface...
 
  I've made the Linkage to go from the Aileron horn to the Bellcranks... They are 11" center to center ( Heim )
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  I drew out the wing aileron control horn , and figured the travel needed for it....

I clamped a piece of cardboard behind the bellcrank , and marked where it should stop in both directions...
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                                   Gotta Fly...
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Attachments
HPIM1081.JPG
HPIM1081.JPG (110.89 KiB) Viewed 4119 times
HPIM1085.JPG
HPIM1085.JPG (118.76 KiB) Viewed 4119 times
HPIM1084.JPG
HPIM1084.JPG (100.17 KiB) Viewed 4119 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 "Stops"

Postby planecrazzzy » Thu Oct 29, 2009 5:54 am

Here's a modification I made for the Aileron "Stops"

I just didn't like the "Stock" one.... I think mine is lighter... and out of the way...

I cut a piece of tubing to make them.... Then stacked a little piece on the end for

a higher/taller stopping surface....

To get them in the "exact" spot....  I clamped the piece on the tube with the surfaces "touching"....

Then , pulled the stick over while watching the bellcrank against the cardboard....

and stopped when the hole got over my mark....  Then "tacked" the stop to the control tube....

And I did the same for the otherside....

Two things.... One, the surfaces match perfectly that way.....two , it's easy to set the limit that way....
Attachments
HPIM1086.JPG
This is the aileron "Stop"...
I put it on the Flap assy tube....
and made the stop to fit "close" to the control tube , without touching it
HPIM1086.JPG (93.33 KiB) Viewed 4118 times
HPIM1088.JPG
This is in the neutral position
HPIM1088.JPG (98.34 KiB) Viewed 4118 times
HPIM1089.JPG
The stick is at full left , the "stop" has a solid feel to it....
HPIM1089.JPG (103.35 KiB) Viewed 4118 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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Flap Torque Tube

Postby planecrazzzy » Thu Oct 29, 2009 6:11 am

Hey Guys,
                 OK,  I changed this around and used the Tailwind prints AND the Buttercup prints....

I liked the lighter tube in the Tailwind prints.... I liked the Bushing support in the middle ( BC prints )

and I think the sleeves over the torque tube were mine.... Just for added strenght , since I went with

the thinner wall tube ( 1" X .035 ).... The sleeves were 1-1/8" X .058 .....

End "inserts" in the torque tube were 7/8" X .049 ...
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The Biggest improvement I like.... it can be removed.....

   OK... I have a few pictures... So I'll explain things as they are posted....
Attachments
HPIM1093.JPG
HPIM1093.JPG (120.69 KiB) Viewed 4116 times
HPIM1094.JPG
HPIM1094.JPG (95.82 KiB) Viewed 4116 times
HPIM1095.JPG
HPIM1095.JPG (96.18 KiB) Viewed 4116 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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mo pics

Postby planecrazzzy » Thu Oct 29, 2009 6:17 am

...
Attachments
HPIM1096.JPG
HPIM1096.JPG (82.69 KiB) Viewed 4115 times
HPIM1097.JPG
HPIM1097.JPG (76.23 KiB) Viewed 4115 times
HPIM1098.JPG
HPIM1098.JPG (82.1 KiB) Viewed 4115 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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Center Support

Postby planecrazzzy » Thu Oct 29, 2009 6:33 am

This piece seems important to me.... although, it's not in the Tailwind prints...

The Flaps will need a lot of pressure to apply... ( I made the handle 3" longer because of that )

So this Flap Torque Tube will be getting a lot of force applied in the center....

This bushing should carry the load just fine....

I had to modifiy it so the Torque tube could come out....

Also... I put two "punch marks" on the same ends of the cap and the main piece...

Just in case they aren't perfectly symmetrical...

That's always handy to do.... these things get taken all apart.... painted and whatever...
If they aren't marked good.... it can be a puzzle putting them back together even though they
"FIT" at one time....

That's yer "Tip" fer the Day....
                                                      Gotta Fly...
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Attachments
HPIM1104.JPG
HPIM1104.JPG (104.34 KiB) Viewed 4113 times
HPIM1101.JPG
Checking "Fit-up"... Welding will do a little shrinking... So , it should have "SLIGHT" pressure....after welding , it turned out perfect.
HPIM1101.JPG (100.05 KiB) Viewed 4114 times
HPIM1102.JPG
Welded , smooth turning.
HPIM1102.JPG (91.09 KiB) Viewed 4114 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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Torque tube horns

Postby planecrazzzy » Thu Oct 29, 2009 7:00 am

OK, the Horns call for "Finger Patches"....  This is "my" version....

I "sleeve" the tube  with a bigger heavy wall tube.... and cut it so it distributes the stress.

I weld it completely....

Then ,  I put extra weld passes in the front and back ...
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These had to be made and slid up the tube from the bottom.....

I welded the main tube/horn.... Then slid the reinforcing sleeve into position....
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Attachments
HPIM1105.JPG
The "sleeves" are made from 3/4" X .049 material
HPIM1105.JPG (96.59 KiB) Viewed 3916 times
HPIM1107.JPG
I squashed the sleeves to fit first,
Then I cut out and shaped them, rounded , no sharp corners
HPIM1107.JPG (103.48 KiB) Viewed 3916 times
HPIM1108.JPG
The Horn has been welded, the sleeve is now in place for welding.
HPIM1108.JPG (70.9 KiB) Viewed 3916 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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Flap control Lever

Postby planecrazzzy » Thu Oct 29, 2009 7:15 am

Hey Guys,
               The Buttercup prints doesn't show it needs this "Side" extention.... But "mine" needs it....

( The Tailwind prints shows it needs it )

  Anywho,
               I stopped working on this earlier , until I got the Aileron linkage done in this area....

Now , I can tell how much room I need for my Flap control "rod".....

 Because I needed to extend it out so far.... I put a "bushing" in the Base mount....

This will help support the bolt better...
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.                                                            Gotta Fly...
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Attachments
HPIM1109.JPG
3/8" X .058 bushing
HPIM1109.JPG (88.34 KiB) Viewed 3915 times
HPIM1110.JPG
HPIM1110.JPG (110.14 KiB) Viewed 3915 times
HPIM1111.JPG
My first extention wasn't long enough.... I added more to it...
HPIM1111.JPG (114.03 KiB) Viewed 3915 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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mo pics

Postby planecrazzzy » Thu Oct 29, 2009 7:29 am

I drew out the Control horn for the wing Flap tube.... Figured out the degrees for
grinding the holes in the "Hoop"....
I used a little "ball" die grinding carbide bit.... worked great.

I used the marks on the paper to show me the location....
When you do this.... Be sure to put "flap pressure" on the linkage....
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When I was making the "splice" in the "Hoop".... I figured the head of the
3/16" bolt would end up being the Limit ( 35 degrees )
I missed it by 1/8"......  I made a little cover/sleeve that gets bolted there....( not shown )
Now.... the last flap adjustment has a "stop" ( perfect fit )
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                                   Gotta Fly...
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Attachments
HPIM1113.JPG
HPIM1113.JPG (98.27 KiB) Viewed 3914 times
HPIM1114.JPG
HPIM1114.JPG (109.73 KiB) Viewed 3914 times
HPIM1116.JPG
HPIM1116.JPG (123.91 KiB) Viewed 3914 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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Horns

Postby planecrazzzy » Thu Nov 05, 2009 9:45 pm

Hey Guys,
               Here's the Aileron and Flap Horns.... These are the ones attached on the Wings...
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. I put some re enforcing on the Flap Horns....

                            Gotta Fly...
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Attachments
HPIM1119.JPG
HPIM1119.JPG (113.47 KiB) Viewed 3902 times
HPIM1121.JPG
HPIM1121.JPG (103.45 KiB) Viewed 3902 times
HPIM1122.JPG
HPIM1122.JPG (108.33 KiB) Viewed 3902 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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Rudder Bushing

Postby planecrazzzy » Thu Nov 05, 2009 9:49 pm

Hey Guys,
                This is a little different from the print...

 But it's simple , and Light...

 I used a thinner wall bushing..... and added silicone bronze inside for better "wear"
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                    Gotta Fly...
.
.
.
Attachments
HPIM1126.JPG
HPIM1126.JPG (112.4 KiB) Viewed 3901 times
HPIM1127.JPG
HPIM1127.JPG (91.69 KiB) Viewed 3901 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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Rudder Pedal Assy

Postby planecrazzzy » Thu Nov 05, 2009 9:58 pm

Hey Guys,
                I'm making the Rudder Assy....  But I'm modifying it...

I want to be able to take it apart....  So far , it's working pretty good...
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                           Gotta Fly...
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.
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Attachments
HPIM1134.JPG
HPIM1134.JPG (100.64 KiB) Viewed 3900 times
HPIM1135.JPG
HPIM1135.JPG (100.45 KiB) Viewed 3900 times
HPIM1136.JPG
The "Stub" was TIG welded with wire , Then the Silicone Bronze was added to take up the slop...
HPIM1136.JPG (100.2 KiB) Viewed 3900 times
Last edited by planecrazzzy on Thu Nov 05, 2009 10:02 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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Posts: 758
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mo pics

Postby planecrazzzy » Thu Nov 05, 2009 9:59 pm

...
Attachments
HPIM1137.JPG
HPIM1137.JPG (93.44 KiB) Viewed 3899 times
HPIM1138.JPG
HPIM1138.JPG (92.28 KiB) Viewed 3899 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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Posts: 758
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

mo pics

Postby planecrazzzy » Thu Nov 05, 2009 10:05 pm

...
Attachments
HPIM1139.JPG
HPIM1139.JPG (117.89 KiB) Viewed 3897 times
HPIM1140.JPG
HPIM1140.JPG (114.78 KiB) Viewed 3897 times
HPIM1141.JPG
HPIM1141.JPG (117.39 KiB) Viewed 3897 times
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
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Posts: 758
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

mo pics

Postby planecrazzzy » Thu Nov 05, 2009 10:09 pm

...
Attachments
HPIM1142.JPG
This will be the most "Forward" position the Assy will be at....
HPIM1142.JPG (117.95 KiB) Viewed 3896 times
HPIM1143.JPG
I will probably have two positions to the rear for this Rudder Assy...
Each station will jump one inch...
That will be a three inch adjustment
HPIM1143.JPG (103.48 KiB) Viewed 3896 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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Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

Postby ElliotW » Fri Nov 20, 2009 10:40 am

Mike- I would like to say that your craftsmanship is A+. I was hoping you could explain how you fabricated your Flap Control horns with the flange around the base and  continuing along the lever side?  Form press? Also concerning your TIG setup. What setup has worked best for you with your Wittman build? Cup size/electrode to have access to the real difficult clusters? Tig Braze setup? Thanks for the build log its a great help to see how fabrication is done with top notch craftsmanship.

Elliot W.
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