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Bending a leading edge.
OMG, I know all the hard ways of doing it, but not a simple one that gives great results.
I still have to see these videos myself. I'm new here and I need all the information I can get.
You know about the shop vac method? There's an article in SA about this already - mid 1980's, I think (maybe 1986 or so). They were using it on the Monnett Moni design. This was rediscovered by Sonex builders maybe 5-6-7 years ago, and has caused mass abandonment of house-buckling presses ever since. Seriously, somewhere there's a photo of a Sonex wing leading edge press in someone's garage, where they used house jacks to the ceiling joists to - well, what did you think would happen - the ceiling cracked and the house lifted up... The shop vac method is casual and non-threatening by comparison. One builder already documented this on video - he distributed it via cd for a while, but it might be on a video website by now. If it isn't, it should be...
Hi Charlie,
I'm about to replace the control wires on an Australian Lightwing, an LSA sized rag & tube acft.
While there are a couple of videos that cover Nicopress, tension etc, I come from a marine background where I learnt proper preparation of wire rope so I have some questions which don't seem to be addressed anywhere.
Q1. Does the new control cable wire need to be pre-stretched before making up the cable lengths ? Why/why not ? Method ?
Q1a. If so what stretching tension would you use ? 1/2SWL ? 3/4SWL ?
Q2. When making up the new length should I make any allowance for future stretching ? How much ?
Q3. Is there a trick/jig to make-up the new cable to the same length as the existing cable ? (As simple as a couple of nails in a 4X2 ?)
Q4. What are the advantages/disadvantages of galvanised vs stainless steel wire.
Q5. If I use gal/SS wire should I use Cd or SS thimbles ? Why ?
Q6. What are the pros & cons of bare copper & nickel plated copper swages ? Which should I use for gal/SS wire ?
I'm sure a whole family of videos could be created covering different aspects of this subject.
Other points that could be covered:
Tips for the newby eg swaging one end of every wire first to get practice with the tools & process where you can just cut off a couple of centimetres and start again if you make a mistake. Likewise, finish the long ones first so you can cut them down and use them for the shorter cables if you make a mistake.
Why you heat shrink the wire tail but do not heatshrink the swage.
Why you don't use boat shop aluminium swages.
On a side issue, ongoing maintenance, should the wire be lubricated and if so what is available that won't attract dirt, how should it be applied to get penetration. (Somehow I don't think the lube we used on the mooring cables for a 40,000T container ship would be appropriate.:rollseyes:)
Parallel video(s) could cover making up cables for a new install, what are the options to connect cable to the turnbuckles or fixed points, advantages/disadvantages. Tips & tricks to getting the length right. Choice of cable.
With the move away from externally braced aircraft there is also less expertise readily available on rigging wires. Something on the specifics of rigging wires such as streamline sections v wire might be of interest. How do you measure the tension in a streamline section ?
While I'll have the new cables in the Lightwing before that video(s) could be made, perhaps there are other people out there who would benefit.
Thanks.
Mark
Quote:
Bending a leading edge.
OMG, I know all the hard ways of doing it, but not a simple one that gives great results.
If you search "Bending a Sonex leading edge skin with the vacuum method" on you tube......Quote:
You know about the shop vac method?
These are ideas off the top of my head, I DO NOT know if any of these have been produced already:
Using the "greased plates" method for aligning landing gear
"Cushion" in the movement of Bowden cable type engine controls, and proper routing/clamping of Bowden cable controls
Turnbuckle safety-ing, single and double wrap
Getting fabric covering down around 3D curved surfaces
Getting pinked fabric tape on straight, around wingtips and other curves
Adjusting the balance between thrust line and aerodynamic rigging
Various methods of deburring sheet metal, from classic tools to new-era homebuilder discoveries (scotchbrite wheels)
Step-drilling and reaming structural bolt holes for perfect fit and safety
Setback and other factors for correct sheet metal bending
BTW, congratulations on an incredible idea (the Hints for Homebuilders videos). This is a tremendous resource for builders... Home Run for EAA!
As someone mentioned before, you should consider adding videos for flying airplane maintenance. What about "Hints for Aircraft Owners", or "The Educated Aircraft Owner" videos, assisting pilots and owners of Cessna/Piper aircraft as well. This is a low-cost opportunity to further solidify EAA's position as the leader in sport aviation,as well as reaching out to pilots who were not otherwise "EAA types".
How to make tube fairings.
I would love to buy some of that material and make some tube fairings, I guess that is what they are called.
This may seem simple for the builder but to me this is a major undertaking. This would be a great how to. I am sure there are tricks to doing this.
It looks as if you just cut a measure then put ends on the new fairings and bolt them into place, But I am sure there is more to this.
There may already be a webinar on this and I have not come across it yet.